Integration of micro-optics with a fiber array connector using passive alignment technique for parallel optics applications

The micro-optic chips are made of glass material using wafer scale photolithography and etching techniques, and micro optical elements are fabricated on both sides. The fiber array connector is an injection molded plastic receptacle, which contains an interface for the MT connector and a precision cavity for passive alignment. For the 12-channel transmitter optical sub-assembly (OSA), we incorporated 12 diffractive lenses for mode launching and reduction of back reflection, and 12 refractive lenses for laser fiber coupling; for the 12-channel receiving OSA, we incorporated 12 refractive lenses for collimating and 12 refractive lenses for focusing. This product design would also be suitable for a 4+4 parallel transceiver OSA. For parallel transmitter or transceiver applications, we incorporated a patented vortex mode launching DOE, also called a "Bandwidth Lens™", which can optimize and improve the bandwidth×distance product of multi-mode fiber by a factor of 1.5×-2×. This vortex lens also reduces the back reflection. To reduce manufacturing cost, we implemented a passive alignment technique for the integration of micro-optics and a fiber array connector. In this paper, we also present our optical/mechanical tolerance analysis based on ray-tracing simulations and functional test data.