Optical sensor modules and methods of fabrication are described. In an embodiment, an optical component is mounted on a module substrate. In an embodiment, a pillar of stacked wireballs adjacent the optical component is used for vertical connection between the module substrate and a top electrode pad of the optical component.

A method and device for interconnecting optical components, such as optical fibers and optical circuits, in a flexible, repeatable, and cost-effective manner. Two or more optical components are interconnected by a flexible optical circuit substrate bearing one or more embedded optical fibers with a lens at each end of each fiber. The flexible optical circuit may be incorporated into a housing bearing apertures for receiving the optical connectors of the optical components that are to be interconnected with the device. The lensed ends of the fibers embedded in the flexible optical circuit are positioned adjacent to the apertures for optically connecting to the fibers within the connectors installed in the apertures without conventional mating connectors disposed inside the housing.

A tool for producing a lamp body includes a tool head having an optical waveguide exit opening, an optical waveguide provision device for providing an optical waveguide at the optical waveguide exit opening, and a positioning element which has an optical waveguide guide surface and is displaceable along an axis that extends at a distance from the optical waveguide exit opening.

A fixture is for forming a fiber optic array that defines a plurality of discrete fibers extending from a spaced-apart arrangement to a consolidated arrangement wherein the fibers are layered next to each other for a further ribbonizing process. The fixture includes a pair of contact blades that are configured to slide along a direction transverse to the longitudinal axes of the fibers for consolidating the fibers.

A method and device for interconnecting optical components, such as optical fibers and optical circuits, in a flexible, repeatable, and cost- effective manner. Two or more optical components are interconnected by a flexible optical circuit substrate bearing one or more embedded optical fibers with a lens at each end of each fiber. The flexible optical circuit may be incorporated into a housing bearing apertures for receiving the optical connectors of the optical components that are to be interconnected with the device. The lensed ends of the fibers embedded in the flexible optical circuit are positioned adjacent to the apertures for optically connecting to the fibers within the connectors installed in the apertures without conventional mating connectors disposed inside the housing.

A method of preparing a preformed fiber optic circuit for later termination to at least one fiber optic connector includes providing a substrate for supporting a plurality of optical fibers, the substrate including at least one layer of flexible foil, wherein the flexible foil may be formed from polyethylene terephthalate (PET) according to one example and peeling a layer including at least the optical fibers from the at least one layer of flexible foil.

A method of preparing a preformed fiber optic circuit for later termination to at least one fiber optic connector includes providing a substrate for supporting a plurality of optical fibers, the substrate including at least one layer of flexible foil, wherein the flexible foil may be formed from polyethylene terephthalate (PET) according to one example and peeling a layer including at least the optical fibers from the at least one layer of flexible foil.

Methods for laser welding one or more optical fibers to a substrate and assemblies are disclosed. In one embodiment, a method of bonding an optical fiber to a substrate having at least one film layer on a surface of the substrate includes directing a laser beam into the optical fiber disposed on the at least one film layer. The optical fiber has a curved surface that focuses the laser beam to a focused diameter. The method further includes melting, using the focused diameter laser beam, a material of the substrate to create a laser bond area between the optical fiber and the surface of the substrate. The laser bond area includes laser-melted material of the substrate that bonds the optical fiber to the substrate. The at least one film layer has an absorption of at least 15% at a wavelength of the focused diameter laser beam.

A cable assembly for optical monitoring is assembled by laying optical fibers into an adhesive layer on a substrate to form an optical circuit. First ends of the fibers are arranged in various groups and second ends of the fibers are arranged in various groups. Groups at a first end of the circuit are spliced to coupler input fibers and coupler output fibers. Groups at the second end of the circuit are terminated at one or more input connectors, one or more output connectors, and one or more monitoring connectors. Some cable assemblies monitor signals received at the input connectors. Other cable assemblies monitor signals received at both the input connectors and the output connectors.

Provided is an optical module comprising a substrate, a holder, and a spacer. An optical waveguide is formed in/on the substrate and end parts thereof are protruding from one surface of the substrate. The holder holds an optical fiber and exposes one end part of the optical fiber in such a manner that the one end part of the optical fiber can be optically connected to the end parts of the optical waveguide at a side of one surface of the holder. The spacer is held the one surface of the substrate and the one surface of the holder.