US6283644B1
Expired / Lapsed
US
⏱️ 0.0 years remaining
Optical package with alignment means and method of assembling an optical package
Assignee: Stratos International Inc
•
Filing: 1999-05-10
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Granted: 2001-09-04
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Expires: 2019-05-10
Abstract
Abstract An optical package is provided including a housing having first and second ends. A ferrule receiving bore is formed in the first end, and an optics cavity is formed in the second end. The optics cavity and the ferrule receiving bore are axially aligned with one another along an optical axis defined by the package. A mounting cap is inserted over the optics cavity and frictionally engages an outer surface of the housing. The end cap includes an endplate and a substrate having an optical device mounted thereon. The ferrule receiving bore includes a longitudinal slot extending generally parallel to the axis of the bore providing radial flexibility to the outer wall. Additionally, a split sleeve is provided for accepting a fiber optic connector ferrule. The split sleeve being insertable and expandable in a ferrule receiving bore of an optical package housing. The split sleeve being retained in the ferrule receiving bore with an adhesive.
Inventors
- 👤 Patrick B. Gilliland
- 👤 Leonid Shatskin
- 👤 Roger Weiss
- 👤 Scott Erickson
- 👤 Theodore Washburn
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-02 04:48
CPC Classifications
G; G02; G02B; G02B6/00; G02B6/24; G02B6/42; G02B6/4201; G02B6/4204; G02B6/4219; G02B6/422; G02B6/4225; G02B6/4236; G02B6/4244; G02B6/4245; G02B6/4292; G02B6/4237; G02B6/4238; G02B6/4251; G02B6/4256; G02B6/4262; G02B6/4263
Claims Analysis
Total Claims: 46
Claim 1
Independent Claim
146 words
An optical housing for receiving a fiber optic connector ferrule and aligning an optical fiber affixed therein with an optoelectronic device, the housing comprising: a first end and a second end; the first end defining an optics cavity configured to receive said optoelectronic device and align the housing therewith; the second end defining an axial bore for receiving said connector ferrule, the optics housing forming an outer wall enclosing the axial bore; the housing including at least one longitudinal slot extending generally parallel to the axis of the bore, and providing radial flexibility to the outer wall; and a ferrule stop located at a distal end of the axial bore, dividing the axial bore and the optics cavity, the ferrule stop including a passage therethrough allowing optical radiation to pass between the bore and the optics cavity, and wherein the outer wall includes an asymmetrical periphery.
Claim 2
Dependent Claim
146 words
An optical housing for receiving a fiber optic connector ferrule and aligning an optical fiber affixed therein with an optoelectronic device, the housing comprising: a first end and a second end; the first end defining an optics cavity configured to receive said optoelectronic device and align the housing therewith; the second end defining an axial bore for receiving said connector ferrule, the optics housing forming an outer wall enclosing the axial bore; the housing including at least one longitudinal slot extending generally parallel to the axis of the bore, and providing radial flexibility to the outer wall; and a ferrule stop located at a distal end of the axial bore, dividing the axial bore and the optics cavity, the ferrule stop including a passage therethrough allowing optical radiation to pass between the bore and the optics cavity, and wherein the outer wall includes an asymmetrical periphery.
Claim 3
Dependent Claim
50 words
The optics housing of claim 1 wherein the outer wall enclosing the bore defines a plurality of longitudinal slots generally parallel to the axis of the bore, such that the second end of the optical housing comprises a segmented barrel allowing radial expansion and contraction of the ferrule receiving bore.
Claim 4
Dependent Claim
57 words
The optics housing of claim 1 wherein the distal end of the ferrule receiving bore is precision molded such that upon insertion of the connector ferrule into the ferrule receiving bore, an inner surface of the outer wall acts against the connector ferrule to precisely align the optical fiber within the connector ferrule with the optoelectronic device.
Claim 5
Dependent Claim
121 words
An optics housing for receiving a fiber optic connector ferrule and aligning an optical fiber affixed therein with an optoelectronic device, the optics housing comprising: a housing having a first end and a second end, a ferrule receiving bore formed in the first end and an optics cavity formed in the second end, the optics cavity being axially aligned with the ferrule receiving bore; and a split sleeve positioned axially in the ferrule receiving bore, the split sleeve having a split along a length of the split sleeve, and wherein a length of the ferrule receiving bore is greater than the length of the split sleeve so as to support the split sleeve along substantially the length of the split sleeve.
Claim 6
Dependent Claim
121 words
An optics housing for receiving a fiber optic connector ferrule and aligning an optical fiber affixed therein with an optoelectronic device, the optics housing comprising: a housing having a first end and a second end, a ferrule receiving bore formed in the first end and an optics cavity formed in the second end, the optics cavity being axially aligned with the ferrule receiving bore; and a split sleeve positioned axially in the ferrule receiving bore, the split sleeve having a split along a length of the split sleeve, and wherein a length of the ferrule receiving bore is greater than the length of the split sleeve so as to support the split sleeve along substantially the length of the split sleeve.
Claim 7
Dependent Claim
33 words
An optics housing according to claim 4 , further comprising an adhesive positioned between the split sleeve and the ferrule receiving bore of the housing for attaching the split sleeve to the housing.
Claim 8
Dependent Claim
153 words
An optics housing for receiving a fiber optic connector ferrule and aligning an optical fiber affixed therein with an optoelectronic device, the optics housing comprising: a housing having a first end and a second end, a ferrule receiving bore formed in the first end and an optics cavity formed in the second end, the optics cavity being axially aligned with the ferrule receiving bore; a split sleeve positioned axially in the ferrule receiving bore, the split sleeve having a split along a length of the split sleeve; and an adhesive positioned between the split sleeve and the ferrule receiving bore of the housing for attaching the split sleeve to the housing, and wherein the split sleeve is made of zirconia, and wherein a length of the ferrule receiving bore is greater than the length of the split sleeve so as to support the split sleeve along substantially the length of the split sleeve.
Claim 9
Dependent Claim
153 words
An optics housing for receiving a fiber optic connector ferrule and aligning an optical fiber affixed therein with an optoelectronic device, the optics housing comprising: a housing having a first end and a second end, a ferrule receiving bore formed in the first end and an optics cavity formed in the second end, the optics cavity being axially aligned with the ferrule receiving bore; a split sleeve positioned axially in the ferrule receiving bore, the split sleeve having a split along a length of the split sleeve; and an adhesive positioned between the split sleeve and the ferrule receiving bore of the housing for attaching the split sleeve to the housing, and wherein the split sleeve is made of zirconia, and wherein a length of the ferrule receiving bore is greater than the length of the split sleeve so as to support the split sleeve along substantially the length of the split sleeve.
Claim 10
Dependent Claim
16 words
An optics housing according to claim 6 wherein the housing is made of a metallic material.
Claim 11
Dependent Claim
16 words
An optics housing according to claim 7 wherein the adhesive is made of an epoxy material.
Claim 12
Dependent Claim
17 words
An optics housing according to claim 5 wherein the split sleeve is made of a plastic material.
Claim 13
Dependent Claim
38 words
An optics housing according to claim 4 wherein the ferrule receiving bore has an inside diameter, and wherein the split sleeve has an unexpanded outside diameter that is less than the inside diameter of the ferrule receiving bore.
Claim 14
Dependent Claim
26 words
An optics housing according to claim 4 wherein the split sleeve has an unexpanded inside diameter that is less than an outside diameter of the ferrule.
Claim 15
Dependent Claim
52 words
An optics housing according to claim 4 wherein the split sleeve has an expanded inside diameter that is greater than or equal to an outside diameter of the ferrule, and wherein, when the split sleeve is attached to the ferrule receiving bore, the expanded inside diameter of the split sleeve is maintained.
Claim 16
Dependent Claim
16 words
An optics housing according to claim 5 wherein the housing is made of a metallic material.
Claim 17
Dependent Claim
16 words
An optics housing according to claim 6 wherein the adhesive is made of an epoxy material.
Claim 18
Dependent Claim
36 words
An optics housing according to claim 4 , further comprising a solder film positioned between the split sleeve and the ferrule receiving bore of the housing for holding the split sleeve in place within the housing.
Claim 19
Dependent Claim
36 words
An optics housing according to claim 4 , further comprising an electroplated material positioned between the split sleeve and the ferrule receiving bore of the housing for holding the split sleeve in place within the housing.
Claim 20
Dependent Claim
15 words
An optics housing according to claim 16 wherein the electroplated material is a nickel compound.
Claim 21
Dependent Claim
15 words
An optics housing according to claim 16 wherein the electroplated material is a copper compound.
Claim 22
Dependent Claim
122 words
An optics housing for receiving a fiber optic connector ferrule and aligning an optical fiber affixed therein with an optoelectronic device, the optics housing comprising: a housing having a first end and a second end, a ferrule receiving bore formed in the first end and an optics cavity formed in the second end, the optics cavity being axially aligned with the ferrule receiving bore; a split sleeve positioned axially in the ferrule receiving bore, the split sleeve having a split along a length of the split sleeve; and an electroplated material positioned between the split sleeve and the ferrule receiving bore of the housing for holding the split sleeve in place within the housing, and wherein the ferrule receiving bore has grooves.
Claim 23
Dependent Claim
122 words
An optics housing for receiving a fiber optic connector ferrule and aligning an optical fiber affixed therein with an optoelectronic device, the optics housing comprising: a housing having a first end and a second end, a ferrule receiving bore formed in the first end and an optics cavity formed in the second end, the optics cavity being axially aligned with the ferrule receiving bore; a split sleeve positioned axially in the ferrule receiving bore, the split sleeve having a split along a length of the split sleeve; and an electroplated material positioned between the split sleeve and the ferrule receiving bore of the housing for holding the split sleeve in place within the housing, and wherein the ferrule receiving bore has grooves.
Claim 24
Dependent Claim
19 words
An optics housing according to claim 4 , further comprising a lead-in insert positioned in the ferrule receiving bore.
Claim 25
Dependent Claim
18 words
An optics housing according to claim 20 wherein the lead-in insert being positioned adjacent to the split sleeve.
Claim 26
Dependent Claim
19 words
An optics housing according to claim 5 , further comprising a lead-in insert positioned in the ferrule receiving bore.
Claim 27
Dependent Claim
18 words
An optics housing according to claim 22 wherein the lead-in insert being positioned adjacent to the split sleeve.
Claim 28
Independent Claim
145 words
A method of inserting a split sleeve into a housing of an optics housing, the housing having a first end and a second end, a ferrule receiving bore formed in the first end and an optics cavity formed in the second end, where the optics cavity is axially aligned with the ferrule receiving bore, the ferrule receiving bore accepts a fiber optic connector ferrule, the optics cavity accepts an optoelectronic device, the method comprising the steps of: placing an adhesive inside the ferrule receiving bore; positioning the split sleeve into the ferrule receiving bore so that an end of the split sleeve does not extend beyond an opening of the ferrule receiving bore so as to support the split sleeve along substantially the length of the split sleeve; inserting a ferrule-shaped tool into the split sleeve; and removing the ferrule-shaped tool from the split sleeve.
Claim 29
Independent Claim
145 words
A method of inserting a split sleeve into a housing of an optics housing, the housing having a first end and a second end, a ferrule receiving bore formed in the first end and an optics cavity formed in the second end, where the optics cavity is axially aligned with the ferrule receiving bore, the ferrule receiving bore accepts a fiber optic connector ferrule, the optics cavity accepts an optoelectronic device, the method comprising the steps of: placing an adhesive inside the ferrule receiving bore; positioning the split sleeve into the ferrule receiving bore so that an end of the split sleeve does not extend beyond an opening of the ferrule receiving bore so as to support the split sleeve along substantially the length of the split sleeve; inserting a ferrule-shaped tool into the split sleeve; and removing the ferrule-shaped tool from the split sleeve.
Claim 30
Dependent Claim
15 words
The method according to claim 24 , further comprising the step of curing the adhesive.
Claim 31
Dependent Claim
22 words
The method according to claim 25 wherein the step of removing the ferrule-shaped tool occurs after the step of curing the adhesive.
Claim 32
Independent Claim
137 words
A method of inserting a split sleeve into a housing of an optics housing, the housing having a first end and a second end, a ferrule receiving bore formed in the first end and an optics cavity formed in the second end, where the optics cavity is axially aligned with the ferrule receiving bore, the ferrule receiving bore accepts a fiber optic connector ferrule, the optics cavity accepts an optoelectronic device, the method comprising the steps of: placing an adhesive inside the ferrule receiving bore; positioning the split sleeve into the ferrule receiving bore; inserting a ferrule-shaped tool into the split sleeve; removing the ferrule-shaped tool from the split sleeve; and spinning the housing about a longitudinal axis of the ferrule receiving bore so as to coat a surface of the ferrule receiving bore with the adhesive.
Claim 33
Independent Claim
137 words
A method of inserting a split sleeve into a housing of an optics housing, the housing having a first end and a second end, a ferrule receiving bore formed in the first end and an optics cavity formed in the second end, where the optics cavity is axially aligned with the ferrule receiving bore, the ferrule receiving bore accepts a fiber optic connector ferrule, the optics cavity accepts an optoelectronic device, the method comprising the steps of: placing an adhesive inside the ferrule receiving bore; positioning the split sleeve into the ferrule receiving bore; inserting a ferrule-shaped tool into the split sleeve; removing the ferrule-shaped tool from the split sleeve; and spinning the housing about a longitudinal axis of the ferrule receiving bore so as to coat a surface of the ferrule receiving bore with the adhesive.
Claim 34
Independent Claim
148 words
A method of inserting a split sleeve into a housing of an optics housing, the optics housing having a first end and a second end, a ferrule receiving bore formed in the first end and an optics cavity formed in the second end, where the optics cavity is axially aligned with the ferrule receiving bore, the ferrule receiving bore accepts a fiber optic connector ferrule, the optics cavity accepts an optoelectronic device, the method comprising the steps of: inserting a ferrule-shaped tool into the split sleeve; positioning the split sleeve into the ferrule receiving bore so as to form a gap between the split sleeve and the ferrule receiving bore; pumping an electroplating solution into the gap formed between the split sleeve and the ferrule receiving bore; electrically charging the housing of the optical package and the electroplating fluid; and removing the ferrule-shaped tool from the split sleeve.
Claim 35
Independent Claim
148 words
A method of inserting a split sleeve into a housing of an optics housing, the optics housing having a first end and a second end, a ferrule receiving bore formed in the first end and an optics cavity formed in the second end, where the optics cavity is axially aligned with the ferrule receiving bore, the ferrule receiving bore accepts a fiber optic connector ferrule, the optics cavity accepts an optoelectronic device, the method comprising the steps of: inserting a ferrule-shaped tool into the split sleeve; positioning the split sleeve into the ferrule receiving bore so as to form a gap between the split sleeve and the ferrule receiving bore; pumping an electroplating solution into the gap formed between the split sleeve and the ferrule receiving bore; electrically charging the housing of the optical package and the electroplating fluid; and removing the ferrule-shaped tool from the split sleeve.
Claim 36
Independent Claim
179 words
A method of inserting a split sleeve into a housing of an optics housing, the housing having a first end and a second end, a ferrule receiving bore formed in the first end and an optics cavity formed in the second end, where the optics cavity is axially aligned with the ferrule receiving bore, the ferrule receiving bore accepts a fiber optic connector ferrule, the optics cavity accepts an optoelectronic device, the method comprising the steps of: inserting a ferrule-shaped tool into the split sleeve so as to form a ferrule/split sleeve assembly, wherein the ferrule-shaped tool is made of an electrically conductive material; placing the ferrule/split sleeve assembly into an electroforming solution; electrically charging the ferrule-shaped tool and the electroforming solution so as to form a solidified layer of the electroforming solution attached to and surrounding the ferrule/split sleeve assembly so as to form an electroplated assembly; removing the electroplated assembly from the electroforming solution; machining the electroplated assembly so as to form the housing of the optical package; and removing the ferrule-shaped tool from the split sleeve.
Claim 37
Independent Claim
179 words
A method of inserting a split sleeve into a housing of an optics housing, the housing having a first end and a second end, a ferrule receiving bore formed in the first end and an optics cavity formed in the second end, where the optics cavity is axially aligned with the ferrule receiving bore, the ferrule receiving bore accepts a fiber optic connector ferrule, the optics cavity accepts an optoelectronic device, the method comprising the steps of: inserting a ferrule-shaped tool into the split sleeve so as to form a ferrule/split sleeve assembly, wherein the ferrule-shaped tool is made of an electrically conductive material; placing the ferrule/split sleeve assembly into an electroforming solution; electrically charging the ferrule-shaped tool and the electroforming solution so as to form a solidified layer of the electroforming solution attached to and surrounding the ferrule/split sleeve assembly so as to form an electroplated assembly; removing the electroplated assembly from the electroforming solution; machining the electroplated assembly so as to form the housing of the optical package; and removing the ferrule-shaped tool from the split sleeve.
Claim 38
Dependent Claim
88 words
An optics housing comprising: a housing having a first end and a second end, a ferrule receiving bore being formed in the first end and an optics cavity formed in the second end, the optics cavity being axially aligned with the ferrule receiving bore; a split sleeve insert molded within the ferrule receiving bore adjacent the first end; a focusing element insert molded within the housing adjacent the ferrule receiving bore; and a mounting ring insert molded at the second end of the housing adjacent the optics cavity.
Claim 39
Dependent Claim
88 words
An optics housing comprising: a housing having a first end and a second end, a ferrule receiving bore being formed in the first end and an optics cavity formed in the second end, the optics cavity being axially aligned with the ferrule receiving bore; a split sleeve insert molded within the ferrule receiving bore adjacent the first end; a focusing element insert molded within the housing adjacent the ferrule receiving bore; and a mounting ring insert molded at the second end of the housing adjacent the optics cavity.
Claim 40
Dependent Claim
15 words
An optics housing according to claim 30 wherein the split sleeve is made of zirconia.
Claim 41
Dependent Claim
15 words
An optics housing according to claim 30 wherein the split sleeve is made of copper.
Claim 42
Dependent Claim
27 words
An optics housing according to claim 30 wherein the mounting ring is formed of a metallic material and includes fingers around which the housing is insert molded.
Claim 43
Dependent Claim
16 words
An optics housing according to claim 30 wherein the focusing element is a sapphire glass ball.
Claim 44
Independent Claim
56 words
A method of forming an optics housing comprising the steps of: forming a transfer mold having areas for receiving a split sleeve, a focusing element and a mounting ring; and injection molding a polymer material into the transfer mold and around the split sleeve, focusing element, and mounting ring in order to form an optics housing.
Claim 45
Independent Claim
56 words
A method of forming an optics housing comprising the steps of: forming a transfer mold having areas for receiving a split sleeve, a focusing element and a mounting ring; and injection molding a polymer material into the transfer mold and around the split sleeve, focusing element, and mounting ring in order to form an optics housing.
Claim 46
Dependent Claim
33 words
The method according to claim 35 , further comprising the steps of: aligning an optoelectronic device at a second end of the optics housing; and bonding the optoelectronic device to the mounting ring.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 2004-09-03 | 2005-03-05 | 2005-09-04 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2008-09-03 | 2009-03-05 | 2009-09-04 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2012-09-03 | 2013-03-05 | 2013-09-04 | $7700.00 | Window Closed / Lapsed |