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 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.

A method of preparing an overmolded optical fiber assembly comprising: (a) placing at least one flexible optical circuit in a bottom mold, said bottom mold defining a bottom overmold cavity having a bottom surface, said at least one flexible optical circuit having a substrate and a plurality of fibers adhered to said substrate, said substrate being disposed within said bottom overmold cavity to define a first space between said substrate and said bottom surface; (b) flowing a polymer in at least said first space; (c) placing a top mold over said substrate, said top mold defining a top overmold cavity and a top surface and a port defined in said top surface to access said top overmold cavity, said substrate defining a second space between said top surface and said substrate; (d) flowing a polymer in at least a portion of said second space; and (e) removing said bottom and top molds to release said overmolded optical circuit.

An optical wiring component includes an optical waveguide component that has a first end surface and a second end surface and includes a plurality of optical waveguides extending from the first end surface to the second end surface, an angle formed by a plane including the first end surface and a plane including the second end surface being 70° or more, a plurality of optical fibers that have a first end and a second end, one or more first optical connectors that are mounted on the first end and fixed to the optical waveguide component at the first end surface by an adhesive agent, and one or more second optical connectors that are mounted on the second end.

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.

An optical-fiber-embedding sheet which is a strip-shaped sheet material containing an optical fiber to be used as a sensor and is configured of a base material and an adhesive layer formed thereover which is to be bonded to a placement object where the optical fiber is to be placed, the optical fiber having been embedded in the adhesive layer. The optical fiber is placed by applying a primer, which is for curing the adhesive layer by a chemical reaction with the adhesive layer, to a placement object for the optical fiber and thereafter applying the optical-fiber-embedding sheet to the portion of the placement object to which the primer has been applied.

A fixture (44/244) is for forming a fiber optic array (10/110/210) that defines a plurality of discrete fibers (12) extending from a spaced-apart arrangement to a consolidated arrangement wherein the fibers (12) are layered next to each other for a further ribbonizing process. The fixture (44/244) includes a pair of contact blades (54/254) that are configured to slide along a direction transverse to the longitudinal axes of the fibers (12) for consolidating the fibers (12).

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.

The present disclosure relates to fiber management systems and methods for facilitating assembling fiber optic devices in an efficient manner by allowing pre-processed and tested optical fibers to be pre-routed on a substrate prior to installation in their corresponding fiber optic devices.

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.