Coupling device having a structured reflective surface for coupling input/output of an optical fiber

Abstract

A coupling device for physically and optically coupling an input/output end of an optical fiber for routing optical signals, to and from optical receiver and/or transmitter. The coupling device includes a structured reflective surface that functions as an optical element that directs light to/from the input/output ends of the optical fiber by reflection, and an optical fiber retention groove structure that positively receives the optical fiber in a manner with the end of the optical fiber at a defined distance to and aligned with the structured reflective surface. The open structure of the structured reflective surface and fiber retention structure lends itself to mass production processes such as precision stamping. The coupling device can be attached to an optical transmitter and/or receiver, with the structured reflective surface aligned to the light source in the transmitter or to the detector in the receiver, and adapted in an active optical cable.

We claim: 
     
         1 . A coupling device for physically and optically coupling an optical fiber for routing optical signals, comprising:
 a base having a structured reflective surface and an optical fiber retention structure defined thereon such that an end face of the optical fiber is located at a predetermined distance from the structured reflective surface along the axis of the optical fiber, wherein an end face of the optical fiber is located at a predetermined distance from the structured reflective surface along the axis of the optical fiber, and wherein the optical fiber retention structure accurately aligns the optical fiber with respect to the structured reflective surface, so that output light from the optical fiber can be reflected by the structured reflective surface to outside the coupling device or input light from outside the coupling device incident at the structure reflective surface can be reflected towards the optical fiber.   
     
     
         2 . The coupling device as in  claim 1 , wherein the optical fiber retention structure comprises a groove provided on the base, wherein the groove is aligned with respect to the structured reflective surface. 
     
     
         3 . The coupling device as in  claim 2 , wherein the groove includes a shoulder that defines a stop to which a portion of the end face of the optical fiber can butt against to define the predetermined distance between the end face of the optical fiber and the structured reflective surface. 
     
     
         4 . The coupling device as in  claim 3 , wherein the groove is precision formed to align the optical fiber with respect to the structured reflective surface. 
     
     
         5 . The coupling device as in  claim 4 , wherein the groove is an open groove. 
     
     
         6 . The coupling device as in  claim 5 , wherein the structured reflective surface and the open groove are formed by stamping a malleable material. 
     
     
         7 . The coupling device as in  claim 6 , wherein the malleable material is metal. 
     
     
         8 . The coupling device as in  claim 1 , wherein the structured reflective surface is concave. 
     
     
         9 . A transmitter/receiver module, comprising:
 a coupling device as in  claim 1 ,   at least one of a light source and a light detector supported with respect to the structured reflective surface, wherein the light source produces the input light to be reflected by the structured reflective surface and the light detector receives the output light reflected by the structured reflective surface.   
     
     
         10 . The module as in  claim 9 , wherein the optical fiber retention structure comprises a groove provided on the base, wherein the groove is aligned with respect to the structured reflective surface. 
     
     
         11 . The module as in  claim 10 , wherein the groove includes a shoulder that defines a stop to which a portion of the end face of the optical fiber can butt against to define the predetermined distance between the end face of the optical fiber and the structured reflective surface. 
     
     
         12 . The module as in  claim 11 , wherein the groove is precision formed to align the optical fiber with respect to the structured reflective surface. 
     
     
         13 . The module as in  claim 12 , wherein the groove is an open groove. 
     
     
         14 . The module as in  claim 13 , wherein the structured reflective surface and the open groove are formed by stamping a malleable material. 
     
     
         15 . The module as in  claim 14 , wherein the malleable material is metal. 
     
     
         16 . The module as in  claim 9 , wherein the structured reflective surface is concave. 
     
     
         17 . The module as in  claim 9 , wherein the light source is part of a transmitter, and the light detector is part of a receiver. 
     
     
         18 . An active optical cable, comprising:
 an optical fiber cable having at least one optical fiber;   a transmitter module as in  claim 9 , physical and optically coupled to a first end of the optical fiber; and   a receiver module as in  claim 9 , physically and optically coupled to a second end of the optical fiber.   
     
     
         19 . A process of making the coupling device of  claim 1 , comprising:
 stamping a base to form a structured reflective surface and an optical fiber retention structure.   
     
     
         20 . The process of  claim 19 , wherein the optical fiber retention structure comprises a groove provided on the base, wherein the groove is aligned with respect to the structured reflective surface.