Optical subassembly with passive optical alignment

Claim 1

An optical subassembly comprising an active optical device; an optical fiber; and a lens for providing coupling between said active optical device and said optical fiber CHARACTERIZED IN THAT the subassembly further comprises a first substrate for supporting the active optical device and including a plurality of alignment fiducials disposed at predetermined locations with respect to said active optical device location; a second substrate, comprising top and bottom major surfaces, the top major surface formed to inculde a plurality of alignment fiducials which align with the first substrate alignment fiducials upon attachment of said second substrate to said first substrate and further including an opening to accommodate said active optical device upon mating, and the bottom major surface including an aperture, aligned with and exposing the top surface opening, the bottom surface aperture for holding the coupling lens; an optical header for supporting the combination of said first and second substrates and providing electrical connections to said active optical device; and an optical fiber receptacle including an axial bore for accommodating the optical fiber, said receptacle formed to attach to the optical header in a manner such that the coupling lens is captured within the axial bore and the optical fiber is optically aligned with the combination of said first and second substrates.

Claim 9

A method of assembling components within an optical subassembly in a manner whereby passive optical alignment between the components is achieved, the method comprising the steps of: a) providing an active optical device, an optical fiber and a lens for providing coupling between said active optical device and said optical fiber; b) forming a first substrate to support said active optical device and including a first plurality of alignment fiducials disposed at predetermined locations with respect to said active device location; c) forming a second substrate to support said coupling lens and including a second plurality of alignment fiducials; d) attaching said first substrate to said second substrate in a manner whereby the first plurality of alignment fiducials mate to and are aligned with the second plurality of alignment fiducials, resulting in passive optical alignment between said active optical device and said optical fiber; e) forming an optical fiber receptacle to include an axial bore formed within a predetermined tolerance about the center of said receptacle; and f) mating said optical fiber receptacle to the attached combination of said first and second aligned substrates of step d).

Claim 10

A method of assembling components within an optical subassembly in a manner whereby passive optical alignment between the components is achieved, the method comprising the steps of: a) providing an active optical device, an optical fiber and a lens for providing coupling between said active optical device and said optical fiber; b) forming a first substrate to support said active optical device and including a first plurality of alignment fiducials disposed at predetermined locations with respect to said active device location; c) forming a second substrate to support said coupling lens and including a second plurality of alignment fiducials; d) attaching said first substrate to said second substrate in a manner whereby the first plurality of alignment fiducials mate to and are aligned with the second plurality of alignment fiducials, resulting in passive optical alignment between said active optical device and said optical fiber; e) forming an optical fiber receptacle to include an axial bore formed within a predetermined tolerance about the center of said receptacle; and f) mating said optical fiber receptacle to the attached combination of said first and second aligned substrates of step d).

Claim 12

The method of claims 8 or 9 wherein in performing steps b) and c), pyramidal detents are formed as alignment fiducials.