Optical fiber connector and method of manufacturing the same

Claim 1

An optical fiber connector, comprising: a lower plate having a first upper flat surface, a second upper flat surface being lower than said first upper flat surface, and a stepped portion interposed between said first and second upper flat surfaces and having a transversely-extending side surface; a first upper plate disposable on or above said first upper flat surface and having a bottom flat surface; at least one longitudinally-extending V-groove, formed in one of said upper flat surface of said lower plate and said bottom surface of said first upper plate, for accommodating respective corresponding optical fibers of an optical fiber cable; and a second upper plate provided with an accommodation groove having an opening at each end thereof, for accommodating a covering of said optical fiber cable, said second upper plate having an end surface and being disposable on said second upper flat surface of said lower plate so that said end surface contacts said side surface of said stepped portion.

Claim 7

A method of fabricating an optical assembly, comprising the steps of: (a) preparing an optical fiber connector, comprising: a lower plate having a first upper flat surface provided with at least one longitudinally-extending V-groove for accommodating respective corresponding optical fiber of an optical fiber cable, and a reference upper flat surface, said first upper flat surface and said reference upper flat surface having the same surface; and an upper plate, disposable on or above said upper flat surface, said reference upper flat surface not being covered by said upper plate; (b) positioning said optical fiber in said corresponding V-groove; (c) firmly holding said optical fiber in said corresponding V-groove by disposing said upper plate on or above said upper flat surface, so as to form an optical fiber assembly; and (d) coupling said optical fiber connector assembly with another optical component using said reference upper flat surface as a positioning reference, thereby forming an optical assembly.

Claim 8

A method of manufacturing an optical fiber connector, comprising the steps of: (a) preparing a wafer having a first upper flat surface; (b) forming, in said first upper flat surface, a plurality of groups of longitudinally-extending V-grooves, each V-groove for receiving respective corresponding optical fibers of optical fiber cables; (c) forming, in said first upper flat surface, a second upper flat surface and a stepped portion, said second upper flat surface being lower than said first upper flat surface, said stepped portion having a side surface, and said side surface being interposed between said first and second upper flat surfaces; (d) forming an integral upper plate formed to fit to said side surface of said stepped portion and to said second upper flat surface; (e) forming, in said integral upper plate, a plurality of accommodation grooves respectively corresponding to said plurality of groups of longitudinally-extending V-grooves, for accommodating respective corresponding covering of said optical fiber cables, each said accommodation groove having an opening at each end thereof; (f) positioning and securing said integral upper plate on said second upper flat surface; and (g) cutting said integral upper plate and said wafer together at least in parallel to the extending direction of said V-grooves, so as to form a plurality of optical fiber connector frames respectively having a lower plate provided with said first upper flat surface in which said V-grooves are formed, said second upper flat surface and said stepped potion interposed between said first and second upper flat surfaces, and an upper plate secured on said second upper flat surface and having said accommodation groove.

Claim 9

A method of manufacturing an optical fiber assembly, comprising the steps of: (a) preparing a wafer having a first upper flat surface; (b) forming, in said first upper flat surface, a plurality of groups of longitudinally-extending V-grooves for accommodating respective corresponding optical fibers of optical fiber cables; (c) forming, in said first upper flat surface, a second upper flat surface and a stepped portion, said second upper flat surface being lower than said first upper flat susface, said stepped portion having a side surface, and said side surface being interposed between said first and second upper flat surfaces; (d) forming an integral upper plate formed to fit to said side surface of said stepped portion and to said second upper flat surface; (e) forming, in said integral upper plate, a plurality of accommodation grooves respective corresponding to said plurality of groups of longitudinally-extending V-grooves, for accommodating respective corresponding covering of said optical fiber cables, each said accommodation groove having an opening at each end thereof; (f) positioning and securing said integral upper plate on said second upper flat surface; (g) respectively inserting optical fiber cables into corresponding said accommodation groove and positioning said optical fiber in said corresponding V-groove; (h) firmly holding said optical fibers in said corresponding V-grooves by at least one optical fiber holding plate, so as to form an integral optical fiber connector assembly block; (i) subjecting said assembly block to an end face polishing treatment: (j) cutting said assembly block at least in parallel to the extending direction of said V-grooves, so as to form a plurality of optical fiber assemblies.