Optical coupling efficiency detection assembly and method of assembling the same

1. An assembly method for an optical coupling efficiency detection assembly, the assembly method comprising:

providing a beam splitter and a fiber port in a first housing;

providing a ferrule enclosing a monitoring fiber in a second housing;

rigidly attaching the first housing to a planar first side of an attachment block; and

rigidly attaching the second housing to a planar second side of the attachment k that is adjacent to the first side of the attachment block to establish a parfocal arrangement among the beam splitter; the fiber port, and the ferrule;

positioning the second housing relative to the first housing to form the parfocal arrangement; and

immobilizing the second housing relative to the first housing by bonding the attachment block to the first housing and the second housing;

wherein the positioning comprises:

directing a light beam from a condenser into the beam splitter to split and couple the light beam simultaneously into an alignment fiber installed at the fiber port and the monitoring fiber at the ferrule;

adjusting a position of the condenser to align the light beam with the beam splitter and the fiber port;

detecting a coupling efficiency at the monitoring fiber; and

adjusting a position of the second housing to optimize the coupling efficiency at the monitoring fiber.

2. The assembly method of claim 1 , wherein the immobilizing comprises:

applying a bonding adhesive on a first attachment surface forming a part of the planar first side of the attachment block;

applying the bonding adhesive on a second attachment surface forming a part of the planar second side of the attachment block; and

positioning the first attachment surface to the first housing and the second attachment surface to the second housing to bond the attachment block to the first housing and the second housing.

3. The assembly method of claim 2 , further comprising:

applying a first biasing force on the attachment block toward the first housing during a curing process of the bonding adhesive; and

applying a second biasing force slightly greater than a weight of the attachment block on the attachment block toward the second housing during the curing process of the bonding adhesive.

4. The assembly method of claim 2 , wherein the bonding adhesive has a thermal expansion coefficient equal to or less than that of the first housing, the second housing, and the attachment block.

5. The assembly method of claim 2 ,

wherein first abutment pads are disposed along a perimeter portion of the first attachment surface and second abutment pads are disposed along a perimeter portion of the second attachment surface, and

wherein the bonding adhesive is titrated on a center portion of the first attachment surface and a center portion of the second attachment surface, such that the bonding adhesive does not interfere with the first and the second abutment pads.

6. The assembly method of claim 1 , wherein each of the first housing, the second housing, and the attachment block comprises precision metal material.

7. An assembly method for an optical coupling efficiency detection assembly, the assembly method comprising:

providing a beam splitter and a fiber port in a first housing;

providing a ferrule enclosing a monitoring fiber in a second housing;

rigidly attaching the first housing to a planar first side of an attachment block; and

rigidly attaching the second housing to a planar second side of the attachment block that is adjacent to the first side of the attachment block to establish a parfocal arrangement among the beam splitter, the fiber port, and the ferrule:

positioning the second housing relative to the first housing to form the parfocal arrangement; and

immobilizing the second housing relative to the first housing by bonding the attachment block to the first housing and the second housing;

wherein the immobilizing comprises:

applying a bonding adhesive on a first attachment surface forming a part of the planar first side of the attachment block;

applying the bonding adhesive on a second attachment surface forming a part of the planar second side of the attachment block; and

positioning the first attachment surface to the first housing and the second attachment surface to the second housing to bond the attachment block to the first housing and the second housing;

wherein first abutment pads disposed on the first attachment surface contact the first housing and second abutment pads disposed on the second attachment surface contact the second housing when the attachment block is attached to the first housing and the second housing.

8. The assembly method of claim 7 ,

wherein the first abutment pads are disposed along a perimeter portion of the first attachment surface and the second abutment pads are disposed along a perimeter portion of the second attachment surface, and

wherein the bonding adhesive is titrated on a center portion of the first attachment surface and a center portion of the second attachment surface, such that the bonding adhesive does not interfere with the first and the second abutment pads.

9. The assembly method of claim 7 , further comprising:

applying a first biasing force on the attachment block toward the first housing during a curing process of the bonding adhesive; and

applying a second biasing force slightly greater than a weight of the attachment block on the attachment block toward the second housing during the curing process of the bonding adhesive.

10. The assembly method of claim 7 , wherein the bonding adhesive has a thermal expansion coefficient equal to or less than that of the first housing, the second housing, and the attachment block.

11. The assembly method of claim 7 , wherein each of the first housing, the second housing, and the attachment block comprises precision metal material.

12. An assembly method for an optical coupling efficiency detection assembly, the assembly method comprising:

providing a beam splitter and a fiber port in a first housing;

providing a ferrule enclosing a monitoring fiber in a second housing;

rigidly attaching the first housing to a planar first side of an attachment block; and

rigidly attaching the second housing to a planar second side of the attachment block that is adjacent to the first side of the attachment block to establish a parfocal arrangement among the beam splitter, the fiber port, and the ferrule;

positioning the second housing relative to the first housing to or the parfocal arrangement; and

immobilizing the second housing relative to the first housing by bonding the attachment block to the first housing and the second housing;

wherein the immobilizing comprises:

applying a bonding adhesive on a first attachment surface forming a part of the planar first side of the attachment block;

applying the bonding adhesive on a second attachment surface forming a part of the planar second side of the attachment block; and

positioning the first attachment surface to the first housing and the second attachment surface to the second housing to bond the attachment block to the first housing and the second housing:

detecting a coupling efficiency at the monitoring fiber; and

adjusting a position of the second housing to optimize the coupling efficiency at the monitoring fiber during a curing process of the bonding adhesive.

13. The assembly method of claim 12 ,

wherein first abutment pads are disposed along a perimeter portion of the first attachment surface and second abutment pads are disposed along a perimeter portion of the second attachment surface, and

wherein the bonding adhesive is titrated on a center portion of the first attachment surface and a center portion of the second attachment surface, such that the bonding adhesive does not interfere with the first and the second abutment pads.

14. The assembly method of claim 12 , further comprising:

applying a first biasing force on the attachment block toward the first housing during a curing process of the bonding adhesive; and

applying a second biasing force slightly greater than a weight of the attachment block on the attachment block toward the second housing during the curing process of the bonding adhesive.

15. The assembly method of claim 12 , wherein the bonding adhesive has a thermal expansion coefficient equal to or less than that of the first housing, the second housing, and the attachment block.

16. The assembly method of claim 12 , wherein each of the first housing, the second housing, and the attachment block comprises precision metal material.