A process for preparing a ferrule assembly

FIELD OF INVENTION

0001The present invention relates generally to an optical component, and, more specifically, to a ferrule-containing optical connector.

BACKGROUND OF INVENTION

0002Optical fiber connectors are an essential part of substantially all optical fiber communication systems. For instance, optical connectors are used to join segments of fiber into longer lengths, to connect fiber to active devices such as radiation sources, detectors and repeaters, and to connect fiber to passive devices such as switches and attenuators. The principal function of an optical fiber connector is to hold a fiber end such that the core of the fiber is axially aligned with the optical path of the component to which the connector is mated (e.g., another fiber, a planar waveguide, or an opto-electric device). This way, light from the fiber is optically coupled to the other component.

0003It is well known that to effect optical coupling and minimize Fresnel loss, "physical contact" should be made between the fiber end and the optical path of the mating device. To effect physical contact, traditionally optical connectors have employed a "ferrule," which is a well-known component for holding one or more fibers such that the fiber ends are presented for optical coupling. Ferrule connectors typically bias the ferrule forward such that, when the connector is mated to a mating component, a mating face of the ferrule urges against the mating component to physically contact the fiber end face with the optical path of the mating component.

0004To effect such physical contact, a conventional ferrule typically requires polishing. A polished ferrule may best be described by way of contrast to an unpolished ferrule. An unpolished ferrule has a geometry and anomalies on its mating face which make it difficult, if not impossible, to bring the end face of fiber housed therein into physical contact with the optical path of the mating component. In addition, when multiple fibers are affixed to an unpolished ferrule, the positions of the fiber ends tend to vary along the mating axis, thereby making it difficult to effect optical coupling with all of the fibers. Polishing the mating face of the ferrule tends to minimize these variances and shape the mating face of the ferrule to present the fiber ends in an even plane for mating.

0005Unfortunately, to minimize the variances and shape the ferrule, polishing must be performed to exacting standards. Polishing therefore tends to be costly and prone to reworking and waste, thereby lowering yields. The problems associated with polishing the ferrule are exasperated in multi-fiber ferrules which are more complicated to polish.

0006Therefore, there is a need for optically coupling a fiber-containing ferrule to an optical path of a mating component without polishing the ferrule. The present invention fulfills this need among others.

0007A ferrule assembly process is described in patent <patcit id="pcit0001" dnum="US6331081B1"><text>US 6331081 B1</text></patcit> in which first coating is removed from optical fibers, then the fibers are cleaved, then burrs are removed from the cleaved fibers, then the fibers are inserted into a ferrule so as to project from a mating face thereof and finally the fibers are fixed relative to the ferrule with adhesive.

0008Patent <patcit id="pcit0002" dnum="US5966485A"><text>US 5,966,485</text></patcit> discloses a further method of preparing a ferrule assembly in which a laser is used to remove a portion of an optical fiber core and cladding projecting from a ferrule after the optical fiber has been adhered to the ferrule. Following this step, the ferrule and fiber ends are polished. Patent <patcit id="pcit0003" dnum="EP0860722A2"><text>EP 0,860,722 A2</text></patcit> discloses a further ferrule assembly method in which a fiber is stripped and fixed in a ferrule. The end of the ferrule is then laser cleaved ground and polished. Patent <patcit id="pcit0004" dnum="GB2356066A"><text>GB 2356066A</text></patcit> discloses an optical fiber assembly in which a metallic sleeve is press-fitted over the end of cladding of an optical fiber cord and surrounds a ferrule which has a polished mating end and accommodates an optical fiber of the optical fiber cord. Patent <patcit id="pcit0005" dnum="WO0229461A1"><text>WO 02/29461 A1</text></patcit> discloses a ferrule assembly in which an optical fiber is held in a ferrule and back-scattering of light is effected by either a roughened ferrule end or scattering elements in a coupling medium at the end of the ferrule.

SUMMARY OF INVENTION

0009The present invention provides a process for preparing a ferrule assembly according to claim 1 that overcomes the aforementioned problems and offers enhanced configurability. Specifically, the applicants have developed an approach for terminating a fiber in a ferrule which separates the functions of preparing the fiber's end face for optical coupling and positioning the fiber within the ferrule. This is a departure from conventional approaches in which the two functions are performed in a single polishing step. By treating the functions individually, the fiber end face can be prepared independent of the ferrule, thereby eliminating the need to polish the ferrule/fiber assembly. The fiber is cleaved after it is disposed in the ferrule to minimize handling of the fiber end face which can blemish or otherwise optically degrade the end face. Furthermore, since the ferrule assembly is not subject to polishing, the axial position of the end face relative to the ferrule can be addressed independently from its preparation. This facilitates precise axial positioning of the fiber end face relative to the ferrule. Generally, it is preferred to have the fiber end face protrude from the ferrule to enhance its ability to make physical contact for optical coupling.

0010According to the invention there is provided a process for preparing a ferrule assembly comprising (a) positioning at least one fiber having an end portion in a ferrule having an unpolished mating face such that said end portion of said fiber extends beyond said unpolished mating face of said ferrule; (b) after step (a), laser cleaving said end portion of said fiber to define a cleaved end face; (c) after step (b) moving said fiber backward relative to said ferrule such that the distance that said cleaved end face protrudes from the mating face of said ferrule changes from a distance <i>d</i>_o to a distance <i>d_f</i>; and (d) after step (c) affixing said fiber relative to said ferrule.

0011The resulting ferrule assembly may comprise: (a) an unpolished ferrule defining one or more pathways, each pathway being adapted to receive a fiber, and a mating face; and (b) a fiber in each pathway, each fiber having an end face which is suitable for optical coupling. Preferably, the fiber protrudes from the mating face.

0012The resulting ferrule assembly may be part of an optical package comprising: (a) a housing; (b) a ferrule assembly disposed at least partially in the housing, the ferrule assembly comprising at least (i) an unpolished ferrule defining one or more pathways, each pathway being adapted to receive a fiber, and a mating face; and (ii) a fiber in each pathway, each fiber having an end face which is suitable for optical coupling. Preferably, the optical package is a connector.

0013The resulting ferrule assembly may be part of an optical package having a ferrule assembly with an unpolished ferrule in which the fiber end is shaped and the end face of the ferrule is normal to the fiber. The optical package may comprise: (a) a housing having a register surface; (b) a ferrule assembly disposed at least partially in the housing, the ferrule assembly comprising at least (i) an unpolished ferrule defining one or more pathways, each pathway being adapted to receive a fiber, and a mating face normal to the pathways and abutting the register surface of the housing; and (ii) a fiber in each pathway, each fiber having a shaped end face which is suitable for optical coupling. Preferably, the optical package is an expanded beam connector.

0014Unpolished ferrules made according to the invention can mate with other ferrule assemblies having either polished or unpolished ferrules.

BRIEF DESCRIPTION OF DRAWINGS

0015<ul id="ul0001" list-style="none"><li><figref idref="f0001">Fig. 1</figref> is a flow chart of the process of the present invention.</li><li><figref idref="f0002">Fig. 2a</figref> shows the effect of a converging laser beam on a fiber during cutting when the beam is held perpendicular to the fiber.</li><li><figref idref="f0003">Fig. 2b</figref> shows the effect of the same beam as in <figref idref="f0002">Fig. 2a</figref> but at angle α from the fiber.</li><li><figref idref="f0004">Figs. 3a and 3b</figref> show top views of different end face geometries formed through laser cleaving.</li><li><figref idref="f0005">Figs. 4a and 4b</figref> show a preferred approach for laser cleaving when the distance between the ferrule mating face and the fiber end face is small.</li><li><figref idref="f0006">Figs. 5a and 5b</figref> show the mating of a ferrule assembly made according to the present invention with polished ferrules having undercut and protruding fibers, respectively.</li><li><figref idref="f0007">Fig. 6</figref> shows an insert of an expanded beam connector in which the end face of the fiber is angled to reduce back reflection.</li></ul>

DETAILED DESCRIPTION

0016Referring to <figref idref="f0001">Figure 1</figref>, a flow chart 100 depicting an overview of the method of the present invention is shown. In step 101, a ferrule for an optical connector is provided. The ferrule has one or more pathways to receive fibers therein. In step 102, one or more fibers are positioned in the pathways of the ferrule such that a portion of each fiber extends beyond the end face of the ferrule. The process proceeds to step 104 in which the fibers are cleaved. Cleaving the fibers is performed using by laser cleaving. Once cleaved, the process proceeds to step 105, in which the position of the fibers relative to the ferrule is secured, thereby forming the ferrule assembly. As used herein, the term "ferrule assembly" refers to a ferrule having one or more fibers terminated in it. At this point, the process may proceed to step 106, in which the ferrule assembly is incorporated into an optical package which may be, for example, a connector or other ferrule-containing device. Each of these steps is discussed in greater detail below.

0017Step 101 involves providing at least one ferrule. The ferrule comprises one or more pathways, each pathway being adapted to receive a fiber, and a mating face, which, in the final ferrule assembly, presents each fiber end for optical coupling to an optical pathway of a mating component. The pathways may be, for example, bore holes or V-grooves. Such ferrules are well-known in the art and include for example, MT-style ferrules (such as those used in the MT-RJ and Lightray MPX7 ferrules), SC-style ferrules, and LC- and MU-style ferrules.

0018Generally, ferrules are made of ceramic or polymeric material. As the fibers are cleaved before they are affixed to the ferrule, they can be extended well past the mating face of the ferrule such that the cleaving operation does not interfere with the ferrule or vice versa.

0019Laser cleaving, however, tends to impart a great deal of heat in the vicinity of the cleave, which in a preferred embodiment may be less than a half a millimeter from the ferrule. At a typical distance of less than 0.5 millimeters from the end face of the ferrule, and using a typical CO₂-type laser, one can expect the temperature at the ferrule end face to approach that required to ablate optical fiber. Such temperatures are problematic for conventional polymeric materials such as, e.g. PPS, which is used in MT-type ferrules. Specifically, polymeric materials tend to degrade, melt or deform at such temperatures, thereby compromising the physical integrity of the ferrule and distorting it beyond typical allowable tolerances. Furthermore, ceramic materials typically used in ferrules are prone to cracking at such temperatures.

0020Due to the proximity of the laser to the ferrule end face, it is preferable for the material at the mating face of the ferrule (herein "mating face material") to either (a) reflect energy, or (b) absorb the laser energy without damaging the ferrule or the fibers contained therein. With respect to reflecting the laser energy, suitable materials preferably reflect at least 90% of the laser light. Since the reflectivity of a material is dependent on the wavelength of the beam, the choice of mating face material will depend on the type of laser used. For example, copper is well suited for a CO₂ laser. With respect to absorbing the laser energy without deformation or degradation, suitable materials have a heat capacity greater than water. Examples of suitable materials include, for example, high temperature ceramics which are well known.

0021In the embodiment in which a reflective material is used to reflect laser energy, just the end face may comprise such a material, although it may be preferable to form the entire ferrule of such a material from a simplicity standpoint. Likewise, in the embodiment in which an energy-absorbing material is used, the material may be used just at the mating face (providing that an adequate mass of material is present to absorb and dissipate the heat) or the entire ferrule may be made from such a material.

0022As mentioned above, a conventional ferrule end face is typically polished to remove all anomalies therefrom and to present the fiber ends for coupling. However, the ferrule of the present invention does not require such polishing since the fiber ends are polished during the cleaving step 104. Therefore, in a preferred embodiment, the ferrule is unpolished. As used herein, the term "unpolished ferrule" refers to a ferrule that has not been polished or is not polished to the extent typically required to achieve physical contact.

0023An unpolished ferrule in this context has a number of distinguishing characteristics. First, an unpolished ferrule typically has surface anomalies on its end face which tend to interfere with the mating surface of the mating connector or device and prevent end faces of fibers from making physical contact with mating optical pathways. For example, ridges or bumps on the mating face of an unpolished ferrule prevent the mating face from making good physical contact with a perfectly planar surface. Those skilled in the art will understand that these surface anomalies tend to make physical contact in the center of the mating face most difficult, which is particularly problematic since the center of the ferrule is typically where the fibers are located. Obviously, as the mating face of the ferrule becomes larger in area, as with MT ferrules, the probability of surface variations and imperfections increases along with the number of fibers requiring physical contact. Polishing the ferrule removes these surface anomalies. Generally, for an MT connector, the surface irregularities are removed during polishing such that the maximum gap between the mating face of the ferrule and a perfectly flat plane is less than about 0.25 µm. By contrast, an unpolished ferrule may have a gap between its mating face and a perfectly flat plane of greater than about 2.5 µm. Another approach for mitigating the effects of surface anomalies on the mating face is to polish a dome on the mating face such that the fibers are located at the apex of the dome. This guarantees that the end faces of the fibers are on the leading surface on the mating face along the mating axis, and, thus, any anomalies toward the edges of the ferrule will not prevent the fibers from contacting the mating surface. Obviously, an unpolished ferrule has no dome.

0024Polishing the ferrule is also required to cause the fiber end faces to protrude a certain distance from the ferrule's mating face. This is due to the fact that MT ferrules typically comprise a polymer material which tends to abrade more quickly than the fibers during polishing. As the ferrule material abrades around the fibers, the fibers effectively protrude from the mating face. Such a protrusion increases the likelihood of the fiber end faces making physical contact with the mating optical pathway of a mating structure. According to <patcit id="pcit0006" dnum="US5743785A"><text>U.S. Patent 5,743,785</text></patcit>, in a polished ferrule, the ends of the fiber should protrude from the ferrule's mating face by about 0.5 to about 2.5 µm, or, in other terms, from about 0.4 to about 2% of the fiber's diameter. Therefore, with an unpolished ferrule, the fiber protrudes by less than 0.5 µm or by greater than 2.5 µm from the ferrule's mating face, or by less than 0.4% or by greater than 2% of the fiber's diameter.

0025Therefore, as used herein, the term "unpolished ferrule" refers to a ferrule having one or more of the following features: (1) a gap of greater than about 2.5µm between the mating face of the ferrule and a perfectly planar surface, (2) a mating face which is not domed, and (3) a fiber protrusion of less than 0.5 µm or greater than 2.5 µm from the ferrule's mating face, or less than 0.4% or greater than 2% of the fiber's diameter. In samples of 100 or more connectors of the present invention, at least 90% have one or more of these characteristics and at least 70% have two or more of these features.

0026Step 102 involves disposing a fiber in each pathway of the ferrule such that a portion of the fiber extends beyond the end face of the ferrule. Each fiber is positioned such that a sufficient portion extends beyond the end face of the ferrule to facilitate cleaving thereof. One skilled in the art will readily understand to what extent the fibers should be extended past the mating face of the ferrule to facilitate cleaving thereof.

0027Step 104 involves cleaving the fiber. The fiber is cleaved to produce an end face which is suitable for optical coupling. As used herein, an end face that is suitable for optical coupling is one in which has no optical or mechanical defects (e.g. no change in refractive index, no scratches or chips, etc.).

0028Cleaving the fibers is performed by laser cleaving. Methods of performing this polishing are well-known and may include, for example, physical grinding/polishing and "laser polishing" in which a laser is used to melt and thereby smooth the end face of the fiber.

0029A preferred process for laser cleaving is described in <patcit id="pcit0007" dnum="US6246026B"><text>U.S. Pat. No. 6,246,026</text></patcit>, incorporated herein by reference, and pending <patcit id="pcit0008" dnum="US880698A" dnum-type="L"><text>U.S. Application No. 09/880,698</text></patcit>, also incorporated herein by reference.

0030In the laser cleaving process, optical fiber material is ablated rather than melted. This requires the laser to impart sufficient energy into the fiber to effect its immediate sublimation. In general, any laser with a wavelength between 0.1 and 1.5 µm and 8.5 µm to 10 µm can be used for producing the beam for cleaving the fibers. Suitable lasers include, for example, CO₂ and excimer lasers, although a CO₂ laser is preferred. CO₂ lasers have proven particularly advantageous due to the high speed at which they can be operated and resulting cost effectiveness.

0031Balancing the objective of delivering high energy to fiber to ablate the glass is the need to minimize the energy absorbed by the glass surrounding the cut so as to minimize melting adjacent the cut. For this reason, the laser is preferably operated in a pulse mode for cutting the fiber. In the pulse mode, the laser transmits short high-energy pulses of laser light so that the material of the fiber is sublimated. The pulses are very short and have very steep edges, thus, the maximum pulse energy is achieved very rapidly. For example, suitable results have been achieved in which the peak power of the pulse is between about 0.1 and about 1000 watts and the pulse length is greater than about 50 fs. Very good results are achieved with a CO₂ laser (wavelength 10.6 µm) having a pulse length of 35 µs and a peak power of 600 watts.

0032Although operating the laser in pulse mode is preferred generally, particularly with high power lasers such as a CO₂ laser, some application may favor operating the laser in a continuous wave mode. For example, if the contact time between the laser and fiber is decreased, i.e., the laser cuts across the fiber more quickly, it may be desirable to operate the laser in continuous wave mode.

0033Directing the laser beam on the fiber to effect the cut is subject to several variables involving the angle of the beam to the fiber and the axial position of the beam along the fiber. The angle of the beam is defined by two angles α and θ which are defined with respect to the Cartesian coordinate system in which the optical axis of the fiber is along the z axis and the y and z axes are perpendicular to each other and the z axis. Angle α corresponds to the angle of the beam from the y axis, while angle θ corresponds to the angle of the beam from the x axis. For purposes of illustration, the x axis will be considered the horizontal axis and the y axis will be considered the vertical axis unless otherwise stated. It should be understood, however, that this orientation is arbitrary and by no means limits the scope of the invention.

0034Before addressing the particular angles θ and α, an understanding of the geometry of the laser beam and its cutting tendencies through fiber is worthwhile. In a preferred configuration, laser cleaving is performed using a combination of a laser and a convergent lens. This combination produces a beam having an angle of convergence of β from the centerline of the beam. Since the beam is converging and not collimated, its angle of incidence with the fiber is not simply parallel to the beam's centerline. Rather, the beam's perimeter contacts the fiber at an angle β relative to its centerline. In other words, the laser beam can be visualized as a conical beam that contacts the fiber substantially along the perimeter of the cone. Furthermore, the beam's effect on the fiber is not limited to just the area defined by the beam. Heat from the beam extends past the beam and ablates fiber material adjacent to it. The degree to which the adjacent fiber material is affected is a function of the time it is exposed to the beam--the longer the exposure the more material is ablated. Therefore, rather than cutting the fiber along the centerline of the beam, the fiber will be cut along a line which greater than angle β from the beam's center line.

0035For example, referring to <figref idref="f0002">Fig. 2a</figref>, a schematic is shown of a beam 201 having an angle β of convergence and an angle α of zero. Rather than cutting an end face essentially normal to the optical axis 202 of the fiber 200, such a configuration results in an end face 203 having a parabolic profile, which is generally undesirable. More specifically, as the laser cuts from top to bottom, the top 204 of the fiber is subjected to the beam for a longer time than the bottom 205. Additionally, since the beam is converging the beam at the top of the fiber will be wider than at the bottom of the fiber. The combination of longer exposure time and a wider beam results in the aforementioned parabolic profile.

0036To avoid a parabolic profile, the laser must be directed at the fiber at an angle α as shown in <figref idref="f0003">Fig. 2b</figref>. The angle α depends upon the angle of convergence and the cutting time/energy level of the beam. For example, to prepare an essentially normal end face 206, angle α should be about 30° for a CO₂ laser having a peak energy level of about 600 watts.

0037The angle θ is variable and depends upon the desired end face geometry. For example, if a planar end face which is essentially normal to the optical axis of the fiber is desired, then angle θ will be about 0. Often it is preferred to bevel the end face of the fiber, particularly in single mode applications in which it is desirable to minimize back reflection. To this end, a common angle θ for single mode fiber end faces is about 8° as shown in <figref idref="f0004">Fig. 3a</figref> which is schematic top view of a fiber 301. Aside from planar or nearly planar end faces, the laser cleaving approach of the present invention can provide for multifaceted or curved end faces. For example, in a preferred embodiment, laser cleaving can be used to form a wedged-shaped fiber end as shown in <figref idref="f0004">Fig. 3b</figref> which is a schematic top view of a fiber 302. Such a configuration is well suited for optically coupling the fiber with pump-type lasers or other devices which emit or receive an elliptical beam of light.

0038Generally, it is preferred that the beam impinge on the portion of the fiber that extends a distance <i>d</i>o from the mating face of the ferrule. As used herein, the term "distance <i>d</i>_o" refers to the shortest distance between the mating face of the ferrule and the end face of the fiber formed after cleaving. It should be understood that distance <i>d</i>_o is not defined by the distance between the mating face of the ferrule and the centerline of the beam since the beam does not cut along its centerline as discussed above. The distance <i>d</i>_o can vary depending upon the cleaving technique. The distance <i>d</i>_o is relatively uncritical, since the fiber's axial position with respect to the mating face of the ferrule can be adjusted after cutting.

0039It has been found that for a particularly small distance <i>d</i>_o the mating face of the ferrule will interfere with the laser beam. This interference can result in a distortion of the laser beam which can affect the accuracy of the laser cut. Additionally, this interference may result in a greater than desired absorption of energy by the ferrule which may cause it to distort or degrade. Accordingly, in the case of small distance <i>d</i>_o, it may be preferred to use a cleaving configuration as shown in <figref idref="f0005">Figs. 4a and 4b</figref> to avoid this interference. As shown in <figref idref="f0005">Fig. 4a</figref>, a ferrule 401 has a domed or beveled mating face 401 which is angled away from the fiber 404 at an angle ϕ. The beam 402 has a convergence angle β. It is well known that a converging beam will meet and then diverge. In this configuration, the beam is positioned such that cleaving is performed at about the point of convergence or at the waist 403 of the beam. If ϕ is equal to or greater than β and the beam is substantially perpendicular to the fiber, then the beam should avoid the mating face of the ferrule. If the beam is not substantially perpendicular to the fiber, but instead at angle α to the fiber (as is preferred), then the angle ϕ needs to be equal to or greater than α + β.

0040The way in which the fibers and laser beam are moved relative to each other to effect the cuts described above can vary and it is anticipated that any approach which is precise, accurate and repeatable will suffice. In a preferred method, a device is used which maintains angle α between the beam and the fiber and moves the fiber at one or more predetermined angles θ relative to the laser beam. It is within the scope of the present invention, however, to move the laser beam relative to the fiber.

0041The laser cleaving process has a number of advantages over traditional mechanical cleaving approaches. Perhaps the most significant advantage is that laser cleaving produces a very smooth fiber end face so additional machining of the fiber end after cutting--as is normal with mechanical cutting processes--is no longer necessary. Elimination of polishing is very significant. Not only is polishing a difficult and time-consuming task, which is prone to error (and therefore waste), but it also affects the axial position of the fiber end face. That is, polishing grinds or otherwise alters the physical features of the end face and thereby affects the axial position of the fiber end. This effect can be critical in the case of a multi-fiber array (e.g., ribbon cable) in which variation in axial position of the various fibers cannot be tolerated. More specifically, if the end faces are at different axial positions, they are prevented from simultaneously making physical contact with optical paths of the mating component. According to <patcit id="pcit0009" dnum="US5743785A"><text>U.S. Patent 5,743,785</text></patcit>, for an MT ferrule, the end face variation or "delta" among the fibers along the mating axis should be not greater than about 0.4 µm and preferably not greater than about 0.2 µm. Because a laser-cleaved fiber does not need to be polished, the axial position of its end face is not subject to this variation. Laser cleaving typically cleaves the end face with an axial position accuracy of 0.1 µm. Therefore, in an unpolished MT ferrule, the end face delta will typically be no greater than about 0.4 µm, and preferably no greater than about 0.2 µm.

0042In step 105, the fibers are affixed such that their relative position with respect to the ferrule is fixed. Methods of fixing the fibers positioned relative to the ferrules are well-known and include, for example, applying epoxy to the ferrule pathways. Other techniques for fixing the fibers position may include, for example, clamping the fiber in an object which is in fixed relation to the ferrule (see, for example, <patcit id="pcit0010" dnum="US6200040B"><text>U.S. Patent No. 6,200,040</text></patcit> which discloses such a clamping mechanism, i.e., the slice element).

0043The fiber's position is fixed relative to the ferrule after the fibers are cut, and the fiber is moved such that its end face is distance <i>d_f</i> from the mating face of the ferrule. Thus, in the situation where the fiber is cleaved a distance <i>d</i>_o from the mating face of the ferrule, in step 104, that distance is decreased to <i>d_f</i>:

0044In one embodiment, the mating face of the ferrule is pushed flush against the flat surface so that the distance <i>d_f</i> is equal to 0. Alternatively, it may be preferred to allow the fiber to protrude somewhat from the mating face of the ferrule such that distance <i>d_f</i> is greater than 0. For example, as discussed in detail below, it is recognized that a fiber that protrudes from the mating face of the ferrule is often more likely to make physical contact with the optical path of the mating component. That is, if the fiber protrudes from the mating face, then any anomalies on the mating face which might otherwise prevent the mating face from forming intimate contact with the mating face of the mating component. A protruding fiber does not require such intimate contact between mating faces. Thus, there is no need to deform the ferrule as is often necessary in conventional type physical contact connectors.

0045Aside from avoiding problems associated with forming intimate contact with the mating surface of the ferrule and deforming the ferrule, a protruding fiber also enables physical contact to be made with a mating connector in which the fiber is undercut from the ferrule. That is, it is not uncommon during the polishing process for the end face of the fiber to recede within the ferrule such that the mating face of the ferrule extends beyond the end face of the fiber. Clearly, in such a situation, physical contact with the end face of the fiber is made difficult. However, a fiber that protrudes from the mating face of the ferrule is able to extend into the ferrule of the mating component and make contact with the end face of the fiber contained therein.

0046The ferrule assembly made according to the present invention is uniquely suited to facilitate fiber protrusion since the fiber end and ferrule mating face are not polished simultaneously as in the prior art. Polishing a ferrule and fiber assembly together results generally in a fiber end face which is flush with the ferrule mating face. The approach of the present invention polishes the fiber end independent from the ferrule (in fact, the ferrule is not even polished). Thus, the fiber end position with respect to the ferrule end face is fully configurable.

0047Countering the desire for the fiber to protrude from the mating face of the ferrule, is the recognition that fibers tend to be delicate and subject to damage. The possibility for damage or breakage increases as the fiber length protruding from the mating face of the ferrule increases. Accordingly, it has been found that preferred distances <i>d_f</i> are from about 0 to about 20 µm, and more preferably from about 1 µm to about 5 µm.

0048Positioning the fiber a distance <i>d_f</i> from the mating face of the ferrule can be accomplished in different ways. If distance <i>d_f is</i> about 0, a preferred way to position the fiber is to press the mating face of the ferrule with the fiber protruding therefrom against a flat surface to thereby push the fiber backward relative to the ferrule until it is flush with the mating face of the ferrule. More complicated position approaches are required if the distance <i>d_f</i> is greater than 0. Suitable approaches include, for example, pushing the ferrule to a flat under a small angle or use translation stages, or any other way of moving the fiber while measuring the fiber end face position.

0049In step 106, the ferrule assembly having the fibers cleaved and affixed relative thereto is assembled into an optical package. As used herein, the term "optical package" refers broadly to an assembly comprising a fiber-terminated ferrule assembly and may include, for example, a ferrule-containing connector (e.g., multi-fiber connectors such as the Lightray MPX7 connector, MT-RJ connector, and MTP connector, and single-fiber connectors such as the SC-, FC-, LC-, and MU-type connectors), or a ferrule-containing device (e.g., passive devices, such as, add/drop filters, arrayed wave guide gratings (AWGs), splitters/couplers, and attenuators, and active devices, such as, optical amplifiers, transmitters, receivers and transceivers). As is well known, the ferrule assembly in the optical package holds a fiber end such that the core of the fiber is axially aligned with the optical path of the mating component to which the connector or device is mated. This way, light from the fiber is optically coupled to the other component. The term "optical pathway" as used herein refers to any medium for conducting optical signals, and includes, for example, a fiber or waveguide, a silica or polymeric structure in a substrate, or a silica or polymeric optical component. The term "mating component" refers to an optical package that contains or comprises the optical pathway, and may include, for example, optical connectors and optical devices as mentioned above. A mating component typically comprises a mating surface which is adapted to receive the mating face of the ferrule to optically couple the fiber(s) with the mating optical pathway(s). Such mating surfaces are well known in the art.

0050Optical packages comprising the ferrule assembly made according to the present invention have a number of advantages over traditional ferrule-containing packages. First, as mentioned above, the ferrule assembly of the present invention obviates the need for polishing. This results in significant simplification of the assembly process and a significant reduction in costs. Aside from this advantage, however, the package of the present invention also has performance related advantages over traditional connectors and packages.

0051Perhaps the most significant performance advantage is derived from the configurability of the fiber's protrusion from the ferrule mating face. The protrusion not only allows for the use of an unpolished ferrule but also facilitates mating with an unpolished ferrule. Thus, the ferrule assembly of the present invention does away with the need for polished ferrules entirely, thereby reducing costs among various optical packages. Furthermore, the fiber's protrusion can even be exploited to compensate for uncut of a polished or unpolished ferrule.

0052<figref idref="f0006">Figures 5a and 5b</figref> are schematic views of the ferrule assembly made according to the present invention optically coupling with a polished ferrule having an uncut and a protrusion, respectively. Referring to <figref idref="f0006">Figs. 5a and 5b</figref>, the ferrule assembly 501 of the present invention is shown comprising a ferrule 502 and a fiber 503 disposed therein which protrudes from the mating face 504 of the ferrule 502. In <figref idref="f0006">Fig.5a</figref>, the ferrule assembly 501 is shown making physical contact with a polished ferrule assembly 505 of a mating component. Like the ferrule assembly of the present invention, ferrule assembly 505 has a ferrule 506 and a fiber 507 disposed therein. However, unlike the ferrule assembly of the present invention, fiber 507 does not protrude from the ferrule, but rather is undercut a distance <i>d</i>_u from the mating surface 508 of the ferrule. Although distance <i>d</i>_u is best minimized and preferably zero, the ferrule assembly of the present invention nevertheless can optically couple with mating ferrule assemblies having <i>d</i>_u from 0 to about .5mm. Referring to <figref idref="f0006">Fig. 5b</figref>, the ferrule assembly 501 is shown mating with a ferrule assembly 509 in which a fiber 510 protrudes from the mating surface 511 of a polished ferrule 512.

0053In addition to a connector including a ferrule assembly made according to the present invention being more tolerant of variations in the mating components, it also does not require the same degree of mating force as does a traditional connector. It is well known that to effect physical contact of conventional ferrule-containing connectors, the ferrules must be biased forward such that when mated the ferrules urge against each other. This force is needed to deform the ferrules and ensure physical contact between the fibers therein. The force with which a ferrule contacts a mating ferrule is referred to as the mating force which is significant. The mating force imparted by connectors becomes problematic as the number of connectors on a given substrate increases. For example, a card having many optical connectors can experience significant force to the extent that the card deforms or is forced out of its slot by the mating force of the optical connectors thereon.

0054A connector including a ferrule assembly made according to the present invention does not require such high mating forces. Since the fiber preferably protrudes from the ferrule, there is no need to deform the ferrule to effect physical contact between the fiber end face and the mating component. Therefore, the mating force of the connector of the present invention is less than that required to deform the ferrule therein. The present invention thus offers advantages over polished ferrules not only with respect to simplifying the preparation of a terminated connector, but also with respect to improving the performance of physical contact ferrule connectors.

0055Yet another advantage offered by the present invention over conventional polished ferrules is the fact that the mating face of the ferrule and the end face of the fiber are not interdependent. That is, unlike a conventional polished ferrule, the end face of the fiber can be shaped for particular application without shaping the mating face of the ferrule in a similar fashion. This allows the end face of the fiber to be shaped to enhance optical performance (for example, angled to reduce back reflection), while the mating face of the ferrule remains unpolished and essentially normal to the fiber for easy handling and alignment.

0056This advantage is particularly significant with respect to non-physical contacting optical coupling. Specifically, in certain non-physical contacting optical coupling applications, such as expanded beam connectors, which use a ball lens to optically couple connectors, the ferrule must be precisely positioned within a ferrule holder such that the focal point of the fiber is precisely located relative to the ferrule holder. Precisely positioning the focal point is critical to ensure that light is effectively coupled to and from the fiber. This positioning is typically accomplished by registering a particular surface of the ferrule on a surface of the ferrule holder. In a preferred embodiment, this registration is accomplished by the leading edge of the ferrule "seating" on a register surface or shoulder within the ferrule holder.

0057Although this configuration is adequate for multimode applications in which the ferrule's mating face is polished normal to the fiber, it tends to be unsuitable for conventional single mode applications in which the ferrule's mating face is polished at an angle. Angled polished ferrules are used in single mode applications to reduce back reflection as mentioned above. Angled polished ferrules, however, are asymmetrical-that is, since they are polished at approximately an 8° angle, their leading edge is actually a point along the periphery of the mating face. This asymmetrical aspect of the ferrule makes it difficult for the ferrule to "seat" precisely on a shoulder in a ferrule holder since only the point of the ferrule contacts the shoulder. Although the shoulder could be asymmetrical itself to receive the angled ferrule, such a ferrule holder would be difficult to manufacture and cost prohibitive. Aggravating the imprecision of seating the point of an angled polished ferrule on the shoulder of the ferrule holder is the fact that the point tends to be sharp, especially in small form factor applications, and, consequently, tends to either dig into the shoulder or deform. As the ferrule digs into the shoulder or deforms, the focal point of the fiber relative to the ferrule holder changes, thereby adversely affecting the coupling efficiency of the connector.

0058This problem may be avoided by providing a ferrule assembly in which the fiber has an angled end face, but the ferrule has a normal mating face for easy handling and packaging. For example, referring to <figref idref="f0007">Figure 6</figref>, an insert 60 of an expanded beam connector is shown. The insert 60 contains a ferrule 62 which in turn contains a fiber 61. The fiber 61 comprises an angled end face 66 which is optically coupled with a ball lens 67. The ferrule 62 is precisely positioned within the insert 60 by virtue of a stop 63. More specifically, the stop 63 provides a reference surface for a mating face 65 of the ferrule 62 to butt up against. Those of skill the art will appreciate that, if the ferrule is precisely positioned with respect to the insert 60, the focal point of the fiber 61 will also be precisely positioned relative to the insert. In contrast to a conventional angled polished ferrule, the ferrule 62 shown in <figref idref="f0007">Figure 6</figref> has a mating face 65 normal to the fiber axis. Consequently, the entire perimeter of the mating surface 64 contacts the stop 63 rather than just a single point along the perimeter. This provides for more reliable seating, especially since the entire perimeter of the mating surface is unlikely to dig into the stop 63 (as a point would) and thereby result in the focal point of fiber 61 moving relative to the insert 60.

0059In addition to expanded beam connector applications, the preterminated fiber configuration of the present invention also lends itself to a number of other non-physical contacting applications in which the focal point of the fiber must be controlled precisely by seating the ferrule precisely. Such applications include, for example, optical couplings with active devices, such as VCSEL lasers, and passive devices, such as filters.

0060It should be apparent from the above description that the ferrule assembly of the present invention provides for significant advantages over conventional polished ferrule configuration such as lower cost and simplicity in manufacturing and enhanced versatility with respect to the type of mating components with which it can effect optically coupling. Still other advantages of the ferrule assembly are anticipated.