JP2008040005A - Method of manufacturing polymer optical waveguide - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a polymer optical waveguide, which method can shorten processing time, and permitting low costs and stable mass production. <P>SOLUTION: In the method of manufacturing the polymer optical waveguide 60, a film material 30 is closely stuck on a mold face side of a mold 10 except for both ends of a concave groove part 11 as a lower clad using the mold 10 which has the concave groove part 11 for forming a waveguide core corresponding to a waveguide core pattern form. A curable resin for waveguide core molding is dropped on one end part of the concave groove part 11 and depressurized for suction, to fill the concave groove part 11 with the curable resin. After the curable resin has been cured, the mold 10 is removed from the film material 30, and the film material 30 and the waveguide core 61 having a form corresponding to the end part of the concave groove part 11 are molded in one body. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a polymer optical waveguide, and more particularly, to a method for manufacturing a polymer optical waveguide in which processing time is reduced and costs are reduced.

  Conventionally, in a typical optical waveguide manufacturing method using, for example, a photolithography method, a core pattern of a waveguide core is manufactured by various thin film forming processes such as patterning, exposure / development, and etching. For this reason, there is a big problem that a complicated and many process is required and the production cost is increased. On the other hand, there is a method of producing an optical waveguide by a pattern replication method using a silicone rubber mold (for example, see Patent Document 1).

In these conventional optical waveguide manufacturing techniques, the end face treatment of the waveguide core is generally performed by cutting with a dicing saw. In particular, in order to optically couple the planar light emitting / receiving element and the optical waveguide mounted on the surface, the end portion of the waveguide core is formed by cutting a dicing saw using a dicing blade whose tip is V-shaped or L-shaped. The optical coupling is performed by bonding the lower surface of the optical waveguide and the light emitting / receiving element.
JP 2004-86144 A

  By the way, the conventional polymer optical waveguide manufacturing method has a problem that it takes time to process the waveguide core end, and the processing cost tends to increase. That is, in the conventional polymer optical waveguide, it is necessary to finish the end portion of the waveguide core to a surface roughness of approximately 1/10 or less of the waveguide light wavelength. Therefore, it is necessary to perform precise cutting with a dicing saw using a blade, and further, polishing of the end face of the waveguide core is required separately. In this type of dicing saw cutting, the processing time is determined by the blade feed speed. However, if the blade feed rate is increased too much, only a rough cutting surface can be obtained, which causes light scattering. Therefore, in order to process the waveguide core cutting surface smoothly, the blade feed rate must be set to zero. It was difficult to raise. In addition, in the waveguide core including the 45-degree mirror surface, in addition to the blade for the 45-degree mirror surface, a blade for vertical cut-off is required separately. For this reason, the processing time in the dicing process, including the setup change of the blade, has been a factor.

  On the other hand, in the case of a large optical waveguide of 100 mm length or more rather than a small waveguide of 10 mm length or less, the outer shape of the waveguide film that does not necessarily require the same surface roughness as the optical end face is cut out and processed into a predetermined dimension Then, coupled with the processing of the end portion of the waveguide core, there is a problem that processing time by a dicing saw using a blade is long, and the processing cost is likely to increase. That is, if the feed rate of the blade of the dicing saw is increased too much, the temperature of the cut portion rises and the thermal stress increases. As a result, the cut surface of the polymer optical waveguide is melted to cause deformation such as bending and warping, and dirt is also attached to the blade, which makes it difficult to always obtain stable quality.

  The present invention has been made in order to solve the above-described conventional problems, and can reduce the processing time, and is a polymer optical waveguide that can be stably mass-produced at low cost. An object of the present invention is to provide a manufacturing method.

  The present invention uses a mold having a groove portion corresponding to the pattern shape of the waveguide core, except for both end portions of the groove portion, and tightly adheres a film material serving as a lower clad to the molding surface side of the mold, Dropping a curable resin for forming a waveguide core into one end of the groove, suctioning the pressure through the other end of the groove, and filling the curable resin in the groove, and After the curing of the curable resin, the mold is peeled off from the film material, and the film material and a waveguide core having a form corresponding to the end portion are integrally formed. It exists in the manufacturing method of a molecular optical waveguide.

  According to the above configuration, a part of the curable resin filled in the both end portions of the concave groove portion of the mold is integrated with the end portion of the film material that is in close contact with the mold, and at the same time, is guided onto the integrated curable resin. The waveguide core end can be formed integrally. Thereby, since the waveguide core which has a form corresponding to the edge part of a ditch | groove part can be integrally formed in a film material, it becomes possible to exclude the dicing process of the waveguide core edge part. Reduction of processing time and cost reduction can be achieved, and stable mass production can be achieved by high-quality molding.

  In the method for producing a polymer optical waveguide of the present invention, the portion corresponding to one end of the concave groove has a resin filling port for filling the curable resin, and corresponds to the other end of the concave groove. Using an auxiliary mold having a resin suction port for sucking the curable resin under reduced pressure at a site, closely contacting the auxiliary mold and the mold via the film material, and the resin filling port and the resin suction port By filling the curable resin via the guide, the curable resin for forming the waveguide core can be easily filled, and the surface of the film material serving as the lower cladding can be finished flat.

  As a suitable example of the auxiliary mold, a structure in which the outer peripheral portion of the film material is pressed to be in close contact with the mold can be used. Thereby, it can prevent that air mixes in a type | mold.

  As another preferred example of the auxiliary mold, a mold structure having a microlens shape at a portion corresponding to the end of the concave groove can be used. Thereby, a lens function can be added by a simple manufacturing method.

  As a preferred example of the mold, a mold structure in which a plurality of the concave groove portions are formed in parallel at a predetermined interval can be used. As said film material, the film material which formed the long hole penetrated up and down in the site | part which traverses the edge part of the said several groove part can be used. Thereby, the waveguide core of the array configuration can be easily formed.

  As another preferred example of the mold, a mold structure in which the concave end surface of the concave groove portion has a mirror shape that folds the light propagating through the waveguide core in the direction of the film material can be used. Thereby, for example, a waveguide film having a buried structure having mirror surfaces having a predetermined angle at both ends of the waveguide core can be easily formed. The light condensing performance with respect to the light emitting / receiving element can be enhanced.

  Furthermore, according to the present invention, a metal thin film can be deposited on the mirror-shaped portion of the waveguide core, and the curable resin serving as the upper cladding can be covered and cured over the entire surface of the waveguide core. As a result, stable waveguide performance can be exhibited and the formation of the upper clad is facilitated.

  Furthermore, in the present invention, it is preferable to punch the outer peripheral portion of the polymer optical waveguide. Since the mirror part which makes a predetermined angle at both ends of the waveguide core can be manufactured, it becomes possible to reduce the labor and labor of changing the dicing blade for the inclined surface and for the vertical cut-off, and the dicing process Time can be saved.

  The present invention can achieve a reduction in processing time and cost reduction, and stable mass production.

  Hereinafter, a preferred embodiment of the present invention will be specifically described with reference to FIGS. 1 and 2.

(Method for producing polymer optical waveguide)
FIG. 1 conceptually shows a polymer optical waveguide manufacturing process, and FIG. 2 shows a structural example of a waveguide film manufactured by the manufacturing procedure of FIG.

  The manufacturing method of the polymer optical waveguide in the present embodiment has improved the manufacturing technology of the polymer optical waveguide such as Japanese Patent Application Laid-Open Nos. 2004-86144 and 2004-109927 previously proposed by the present applicants. Is. In these manufacturing techniques, a waveguide film is manufactured by using a mold made of silicone rubber such as polydimethylsiloxane having a groove for forming a waveguide core. Open ends that are open to the side of the mold are formed at both ends of the groove for forming the waveguide core in the mold. One of the open ends of the concave groove is used as a filling port for filling the curable resin, and the other open end of the concave groove is used as a suction port for sucking the filled curable resin under reduced pressure. . For this reason, the core pattern of the manufactured waveguide core has an excessive portion remaining, and the waveguide core end itself that becomes the mirror surface is not formed in a required form. In addition to dicing, in some cases, it was necessary to perform polishing in addition to dicing.

  On the other hand, in the polymer optical waveguide manufacturing method in this embodiment, as shown in FIG. 1, a mold 10 having a groove 11 for forming a waveguide core including an end of the waveguide core is used. Used. As a result, the waveguide core 61 can be formed simultaneously with the formation of the waveguide core end that becomes the mirror surface. As the material of the mold 10, the same material as the mold previously proposed by the applicant or the like can be used.

  In the method of manufacturing the polymer optical waveguide in this embodiment, the film material 30 serving as the lower cladding is brought into close contact with the molding surface side of the mold 10 while leaving both end portions for forming the mirror surface in the concave groove portion 11 of the mold 10. Thus, both ends can be used as a passage for the resin filling port and the resin suction port of the curable resin for core molding, and the filling of the curable resin from the film material 30 side serving as the lower clad of the waveguide film 60 and Suction can be performed.

  As shown in FIGS. 1 and 2, a part of the curable resin filled in both end portions of the concave groove portion 11 of the mold 10 is integrated with the end portion of the film material 30 that is in close contact with the mold 10. The waveguide core end can be integrated on the integrated curable resin. That is, a curable resin is dropped on one end portion of the concave groove portion 11 of the mold 10 and sucked under reduced pressure via the concave groove portion 11 and the other end portion of the concave groove portion 11 to fill the concave groove portion 11 with the curable resin. Harden. After the curable resin is cured, the mold 10 is peeled off from the film material 30 so that the film material 30 and the waveguide core 61 having the waveguide core end can be integrally formed. The surface roughness of the end face of the formed waveguide core is such that the surface roughness of the inner surface of the groove 11 in the mold 10 can be transferred as it is, as is the surface roughness of other portions of the waveguide core 61. Thus, there is an advantage that dicing and polishing of the waveguide core end are not required.

  According to the above manufacturing method, it becomes possible to eliminate the processing of the waveguide core end face, but the core forming curable resin flow path remains at the waveguide core end, It is important to secure a guided light confinement structure in this remaining portion. Therefore, it is preferable to cover the waveguide core end with the film material 30 as much as possible. However, if the end portion of the waveguide core is completely covered with the film material 30, the curable resin cannot be filled in the concave groove portion 11 of the mold 10.

  Therefore, in the polymer optical waveguide manufacturing method according to the present embodiment, as shown in FIG. 1, the edge of the film material 30 and the part 30 of the film material 30 are in close contact with the parting surface of the mold 10 and the film material 30. A gap formed between the concave end edges of the concave groove portion 11 of the mold 10 can be used as a passage for the resin filling port or the resin suction port. The gap is preferably set to about 10 to 200 μm, more preferably about 20 to 100 μm.

  The resin filling port and the resin suction port are arranged corresponding to the position which becomes the lower surface end portion of the completed waveguide film 60 (FIG. 2). When the waveguide film 60 is mounted on an electronic component such as an optical element, the lower surface of the waveguide film 60 is desirably flat. Therefore, it is preferable to use a sheet-like auxiliary mold 20 having a size that covers at least the concave groove portion 11 of the mold 10. As the auxiliary mold 20, a resin filling port 21 filled with a curable resin can be formed in a part corresponding to one end part of the concave groove part 11 of the mold 10, and curable in a part corresponding to the other end part. A resin suction port 22 for sucking the resin under reduced pressure can be formed.

  Similar to the mold 11, the auxiliary mold 20 needs to be peeled off from the waveguide film 60 after the core-forming curable resin is cured. For this reason, as the material of the auxiliary mold 20, it is preferable to use the same material as that of the mold 10 at least in a portion in contact with the curable resin for core molding, and it is particularly desirable to use, for example, polydimethylsiloxane.

  It is important to prevent a large amount of curable resin from flowing into unnecessary parting surface portions other than the molding surfaces of the mold 10 and the auxiliary mold 20. In a state where the mold 10 and the auxiliary mold 20 are in close contact with each other, it is desirable that the flow path communicating from the end of the concave groove portion 11 of the mold 10 to the resin filling port 21 or the resin suction port 22 of the auxiliary mold 20 can be sealed. As an example of the sealing structure, for example, a mold structure for closing a flow path formed in the auxiliary mold 20 or a long hole 31 formed so as to penetrate a portion corresponding to the resin filling port 21 or the resin suction port 22 is provided. A film material 30 can be used. By using the auxiliary mold 20 or the film material 30 having such a structure, the resin filling port 21 and the mold 10 on the resin filling port side in a state where the auxiliary mold 20 and the mold 10 are in close contact with each other through the film material 30. And the passage formed between the auxiliary mold 20, the concave groove portion 11, the passage formed between the mold 10 on the resin suction port 21 side and the auxiliary mold 20, the resin suction port 22, and the concave groove portion 11 of the mold 10 serving as the waveguide core 61. Can be filled with a curable resin. Thereby, the waveguide core 61 of an array configuration can be formed. In this case, the lower surface of the waveguide core end portion of the waveguide film 60 reflects the shape of the molding surface of the auxiliary mold 20. For this reason, the bottom surface of the waveguide film 60 can be flattened by finishing the molding surface portion of the auxiliary mold 20 flat.

  By the way, the end of the waveguide core is not formed at a right angle, but is formed on the mirror surface 62 inclined at an angle of 45 degrees, so that the propagating light traveling in the waveguide core 61 is directed in the out-of-plane direction of the waveguide film 60. Can be folded. By disposing a planar light emitting / receiving element such as VCSEL, LED, PD, etc. on the front end side of the folded propagation light of the waveguide film, the waveguide film 60 and the light receiving / emitting element can be mounted in a plane.

  The polymer optical waveguide produced by the above production method becomes a waveguide film in which the core pattern of the waveguide core 61 is formed on the film material 30 serving as the lower clad. Even if this is the case, a waveguide light confinement structure in which the upper and side surfaces of the waveguide core pattern are air-clad is established. However, in order to exhibit stable waveguide performance, the entire waveguide core has the same refractive index as that of the film material 30. It is desirable to have a structure embedded with a clad having Even in the buried structure, in order to exhibit the function of the 45-degree mirror portion described above, a metal mask 40 is used, and a metal material having a high reflectance is deposited on the 45-degree mirror portion by metal vapor deposition means, and then becomes an upper clad. The entire waveguide core can be covered with a curable resin and cured. As the metal film material, various metals such as aluminum, gold, silver and titanium are preferably used. As the metal mask 40, a metal mask having a plurality of small through holes corresponding to the 45 ° mirror surface for each of a plurality of waveguide cores can be used. In addition, a metal mask 40 having one long through-hole structure can be used. A plurality of waveguide cores 61 may be deposited together through the through-holes of the metal mask 40. It should be noted that the metal deposited on the portion other than the 45-degree mirror portion does not have an adverse effect as long as the light emitting / receiving element is mounted at the correct position.

  In the waveguide film 60 having an embedded structure having a 45-degree mirror surface at both ends produced by the above-described manufacturing method, a microlens structure can be provided for a light emitting / receiving element mounted at a lower position of the 45-degree mirror surface. Thereby, the condensing performance with respect to a light emitting / receiving element can be improved. As the microlens structure, for example, a convex lens shape corresponding to a 45 degree mirror may be used, or a convex cylindrical lens shape may be used. These lens shapes can be easily formed by providing a lens forming recess at a position corresponding to the waveguide core end of the auxiliary mold 20. Similarly, it is easy to add a lens function by providing the curvature of the 45-degree mirror itself with a curvature.

  Since the optical surface is already formed on the waveguide film 60 configured as described above, optically high accuracy is not necessarily required for cutting out the outer shape of the waveguide film 60. Therefore, the outer shape of the waveguide film 60 can be formed at once by a punching process using a die blade called a Thomson type or a big blade type. Compared with the case where a dicing saw is used, the dicing process time can be greatly reduced without depending on the size of the waveguide film 60. Further, even if a part of the optical waveguide is diced with a dicing saw, in particular, since the 45 ° mirror part can be produced by the manufacturing method of the present invention, it is troublesome to replace the dicing blade for 45 ° and for vertical cutting. And labor can be reduced, and the dicing process time can be reduced.

  Hereinafter, more specific embodiments of the present invention will be described with reference to FIGS.

  FIG. 1A to FIG. 1D are explanatory views conceptually showing a production procedure of a polymer optical waveguide which is Example 1 in the present invention, and FIG. 2A is an upper surface of a waveguide film. FIG. 2 and FIG. 2B are side views of the waveguide film.

  In the waveguide film manufacturing process of Example 1, first, as shown in FIG. 1A, a mold 10, an auxiliary mold 20, and a film material 30 are prepared in advance. This mold 10 is formed by forming a layer of a thick film resist (SU-8 manufactured by Micro Chemical Co., Ltd.) on a Si wafer according to a conventional method, having a core cross-sectional dimension of 60 μm square and a length of 120 mm. It is manufactured by using a master disc in which convex portions for forming four straight waveguide cores having a mirror shape are arranged in parallel. In the production of this master, in addition to the process using a thick film resist, for example, a conventional photolithography method, a method of producing by an electrodeposition method or a photo-deposition method already proposed by the present applicant, etc. (Japanese Patent Application No. 2002) -10240), Japanese Patent Application Laid-Open No. 2004-29507, and the above-mentioned patent document 1 can be used. Moreover, in order to make the both ends of the convex part corresponding to a linear waveguide core into a 45-degree mirror shape, it manufactures by the process using a dicing saw. It can also be easily produced by exposure and development using a gradation mask.

  As the mold 10, after applying a release agent on a master for forming a linear waveguide core, polydimethylsiloxane (SYLGARD 184 manufactured by Dow Chemical Co.) is poured onto the master according to a conventional method, and heated at 120 ° C. for 20 minutes. Then, as shown in FIG. 1A, a silicone rubber mold 10 having concave grooves 11 in a form corresponding to the four convex portions for forming the straight waveguide core of the master is produced. Even in the production of the mold, the technique for producing the mold described in the above-mentioned Patent Document 1 and the like previously proposed by the present applicant, etc., except for the processing of both end portions of the concave groove portion 11 corresponding to the straight waveguide core. Etc. can be used.

  On the other hand, as the auxiliary mold 20, as shown in FIG. 1A, the same material as that of the mold 10 is used, and a resin filling port 21 is formed at a portion corresponding to one end of the recessed groove portion 11 of the mold 10. An auxiliary mold 20 made of silicone rubber having a resin suction port 22 at a site corresponding to the other end of the groove 11 is prepared. Even in the production of the auxiliary mold, the auxiliary mold can be obtained by substantially the same production method as the mold production technique described in Patent Document 1 and the like previously proposed by the present applicant.

  Further, as the film material 30 serving as the lower clad, as shown in FIG. 1A, an Arton film (made by JSR, refractive index 1.51) having a thickness of 50 μm is punched using a Thomson blade. To make. The lower clad is formed in an outer shape having substantially the same size as the mold 10 and the auxiliary mold 20, and each of both ends of the lower clad has a width of 300 μm extending over the four concave grooves 11 of the mold 10. The long holes 31 are formed so as to penetrate therethrough. Each of the long holes 31 and 31 is formed at a portion corresponding to the end of the concave groove portion 11 of the mold 10 and the resin filling port 21 or the resin suction port 22 of the auxiliary mold 20.

(Production of waveguide core)
In producing the waveguide core 61, as shown in FIGS. 1A and 1B, the groove 11 of the produced mold 10 is placed facing upward, and a film is formed on the groove 11 of the mold 10. The materials 30 are overlapped and brought into close contact with each other. At this time, it arrange | positions so that the both-ends edge of the film material 30 may be settled in the both ends of the ditch | groove part 11 of the casting_mold | template 10 with the clearance gap of about 40-80 micrometers. Next, the auxiliary mold 20 is superposed on and closely adhered to the mold 10 via the film material 30. At this time, the resin filling port 21 and the resin suction port 22 of the auxiliary mold 20 are located at positions corresponding to the long holes 31, 31 of the film material 30, respectively, and are arranged outside the concave groove portion 11 of the mold 10. To place.

Next, the resin filling port 21 of the auxiliary mold 20 is filled with an epoxy-based ultraviolet curable resin 50 (a refractive index after curing of 1.55 and a viscosity of 500 cPs) serving as the waveguide core 61, and the resin suction port 22 of the auxiliary mold 20 is filled. Through a vacuum at −30 kPa. As shown in FIG. 1B, the ultraviolet curable resin 50 is filled in the long holes 31 of the film material 30 and the recessed grooves 11 of the mold 10 in about 10 minutes using the capillary phenomenon. Next, ultraviolet light having a wavelength of 365 nm and an intensity of 50 mW / cm ² is cured by irradiation through the mold 20 for 15 minutes, and four waveguide cores 61 having mirror surfaces of 45 degrees on both ends are formed on the film material 30. Form. The ultraviolet curable resin 50 filled in the long hole 31 of the film material 30 can be integrally formed so as to constitute a part of the lower surface of the end portion of the waveguide core.

  When depositing a reflective film on the 45-degree mirror surface 62 at the end of the waveguide core, as shown in FIG. 1C, a metal mask 40 having a pair of through-holes 41 and 41 having a width of 60 μm is used. can do. After the auxiliary mold 20 and the mold 10 are peeled from the film material 30 and disposed with the waveguide core forming surface of the film material 30 facing upward, the metal mask 40 penetrates the 45-degree mirror surface 62 of the waveguide core 61. In a state where the long holes 41 are combined, gold can be deposited to a thickness of about 100 nm from the metal mask 40 side toward the 45-degree mirror surface 62 of the waveguide core 61 via the vapor deposition source 42.

(Preparation of upper cladding)
In producing the upper clad, as shown in FIG. 1 (d), an acrylic ultraviolet curing resin 70 (refractive index 1.51, viscosity 500 cPs) serving as the side and upper clad is applied to the upper portion of the waveguide core 61. . A film 80 having a thickness of 50 μm is overlaid on the core pattern of the waveguide core 61, and in the superposed state, the film is irradiated with ultraviolet rays having a wavelength of 365 nm and an intensity of 50 mW / cm ² for 10 minutes to be cured, so that the total thickness becomes 170 μm. Thus, a waveguide film is formed. Then, punching is performed using a Thomson blade, and as shown in FIG. 2, a bidirectional communication waveguide film 60 having a length of 120 mm and containing two waveguide cores 61 can be produced. On both end faces of the waveguide core 61, 45-degree mirror surfaces 62 coated with gold are formed, and a waveguide film for optical interconnection that can be easily mounted in a plane with a light emitting / receiving element can be produced. .

  The insertion loss of the waveguide film 60 shown in FIG. 2 is 3 dB or less, and good performance can be exhibited. When the film 80 on the upper portion of the waveguide core is omitted and the entire thickness is 120 μm, the bending rigidity of the entire waveguide film is lowered, so that the flexibility can be improved. Moreover, since the thickness of the waveguide film is reduced, punching can be performed more easily.

  FIG. 3 is an explanatory view conceptually showing a production process of a polymer optical waveguide that is Embodiment 2 of the present invention. 4 shows an example of the structure of the waveguide film manufactured by the manufacturing process of FIG. 3, FIG. 4 (a) is a top view of the waveguide film, and FIG. 4 (b) is the waveguide. It is a side view of a film. In these drawings, the difference from the first embodiment is that the long hole 31 of the film material 30 is used as the passage of the resin filling port 21 or the resin suction port 22 in the first embodiment. In Example 2, with the parting surface of the mold 10 and the film material 30 in close contact, the gap formed between the edge of the film material 30 and the recessed edge of the groove 11 of the mold 10 is filled with resin. It is used as a passage for the mouth 21 or the resin suction port 22. Note that, in these drawings, the substantially same members as those in the first embodiment are denoted by the same member names and symbols. Therefore, the detailed description regarding these members is omitted.

  In the manufacturing process of the polymer optical waveguide according to the second embodiment, as shown in FIG. 3A, the master, the mold and the auxiliary mold are manufactured in the same manner as the master, the mold and the auxiliary mold described in the first embodiment. 10 and the auxiliary mold 20 can be produced. Instead of the film material 30 having a long hole 31 in accordance with the waveguide core length of 120 mm, the film length is slightly smaller than the size of the parting surface of the mold 10 and the length of the concave groove portion 11 of the mold 10. A film material 30 slightly shorter than 120 mm is prepared in advance. On the other hand, on the mold surface side of the auxiliary mold 20, there is a recessed portion formed at a depth substantially the same as the thickness dimension of the film material 30. A parting surface 23 is formed on the outer periphery of the recessed portion so as to protrude in a square frame shape to about 100 μm. The parting surface 23 is in close contact with the mold 10 with the film material 30 in close contact therewith.

  Even in the manufacturing process of the polymer optical waveguide according to the second embodiment, as shown in FIGS. 3A to 3C, the above-described implementation is performed using the mold 10, the auxiliary mold 20, and the film material 30. The high quality waveguide film 60 shown in FIG. 4 can be manufactured by the same manufacturing process as in Example 1. In the production of the waveguide of the second embodiment, the amount of the film material 30 used can be reduced as compared with the first embodiment.

  FIG. 5 is an explanatory view conceptually showing a production process of a polymer optical waveguide that is Embodiment 3 of the present invention. 6 shows an example of the structure of the waveguide film manufactured in the manufacturing process of FIG. 5, FIG. 6 (a) is a top view of the waveguide film, and FIG. 6 (b) is the waveguide film. FIG. In these figures, the difference from Example 1 is that the vapor deposition process for the 45-degree mirror surface is omitted, that is, a mirror structure using a difference in refractive index between the waveguide core and air is manufactured. Therefore, in these drawings, the substantially same members as those in the first embodiment are denoted by the same member names and reference numerals, and detailed description of these members is omitted.

  Even in the production process of the polymer optical waveguide of Example 3, as shown in FIG. 5A, as in the production technique of the master, the mold, the auxiliary mold, and the long hole film in Example 1 above. The master, the mold 10, the auxiliary mold 20, and the film material 30 can be manufactured. In the production of the waveguide according to the third embodiment, as shown in FIGS. 5A to 5C, the vapor deposition process for the 45-degree mirror surface 62 in the production of the waveguide core 61 is omitted. Further, in the side surface and upper clad manufacturing process, the dropping amount and the dropping position of the ultraviolet curable resin 70 are optimized so that the ultraviolet curable resin 70 serving as the side surface and the upper clad does not contact the 45 degree mirror surface 62. Yes. As a result, a mirror structure in which the 45-degree mirror surface 62 has a total reflection condition due to the refractive index difference between the waveguide core 61 and air can be manufactured.

  Even in the production process of the polymer optical waveguide of Example 3, the high-quality waveguide film 60 shown in FIG. 6 is produced by using the mold 10, the auxiliary mold 20, and the film material 30 in Example 1 above. can do. The insertion loss of the waveguide film 60 is 3 dB or less, and good performance can be exhibited. Even if the formation of the side surface and the upper cladding is omitted, the waveguide film 60 having the same performance as that of the first embodiment can be formed. However, if the formation of the side surface and the upper cladding is omitted, the performance may be remarkably deteriorated when there is a change in the usage environment, for example, adhesion or condensation of dust.

  FIG. 7 is an explanatory view conceptually showing a production process of a polymer optical waveguide that is Embodiment 4 of the present invention. 8 shows an example of the structure of the waveguide film manufactured in the manufacturing process of FIG. 7, FIG. 8 (a) is a top view of the waveguide film, and FIG. 8 (b) is the waveguide film. FIG. FIG. 9 is an explanatory diagram for explaining a mounting form of the waveguide film of FIG. In these figures, a significant difference from the third embodiment is that a cylindrical lens structure is fabricated at the input / output portion of the guided light in the waveguide. In these drawings, substantially the same members as those in the third embodiment are given the same member names and symbols.

  Even in the production process of the polymer optical waveguide of Example 4, as shown in FIG. 7A, as in the production technique of the master, the mold, the auxiliary mold, and the long hole film in Example 3 above. The master, the mold 10, the auxiliary mold 20, and the film material 30 can be manufactured. According to the fourth embodiment, as the auxiliary mold 20, as shown in FIG. 7A, a semi-cylindrical surface shape corresponding to a cylindrical lens shape having a width of 60 μm and a curvature radius of 100 μm in a portion corresponding to the waveguide core end. A material in which the dent 24 is prepared is prepared in advance. Even in the polymer optical waveguide fabrication process of Example 4, as shown in FIGS. 7A to 7C, the high quality shown in FIG. The waveguide film 60 can be produced.

  As shown in FIG. 8B, a cylindrical microlens 63 is formed at the waveguide core end of the waveguide film 60 manufactured by the steps shown in FIGS. 7A to 7C. Can do. As shown in FIG. 9, when the waveguide film 60 is measured using a VCSEL 90 (Fuji Xerox AM0001), the cylindrical microlens 63 collimates the input light in the direction corresponding to the cylindrical shape. For this reason, while being able to reduce the excess loss of the 45 degree | times plane mirror 62 part of the waveguide film 60, the insertion loss is 2.5 dB or less, and can exhibit favorable performance.

  FIG. 10 is an explanatory view conceptually showing a production process of a polymer optical waveguide which is Embodiment 5 of the present invention. FIG. 11 shows an example of the structure of the waveguide film manufactured in the manufacturing process of FIG. 10, FIG. 11 (a) is a top view of the waveguide film, and FIG. It is a side view of a waveguide film. In these drawings, substantially the same members as those in the fourth embodiment are given the same member names and symbols.

  Even in the manufacturing process of the polymer optical waveguide of Example 5, as shown in FIGS. 10A to 10C, the process similar to that of Example 4 described above is performed. A high-quality waveguide film 60 shown in (b) can be produced. In the fifth embodiment, not the cylindrical microlens 63 as in the fourth embodiment but each spherical microlens 64 having an array configuration is provided at a position corresponding to the 45-degree mirror surface 62. If a spherical microlens 64 is provided as in the illustrated example, even better performance can be achieved. However, in this case, it is necessary to reliably perform alignment adjustment for aligning the position of the spherical microlens array 64 with the 45-degree mirror surface 62. Therefore, it takes a little more time to set the auxiliary mold 20 having the hemispherical recess 25 corresponding to the shape of the spherical microlens.

  FIG. 12 is an explanatory view conceptually showing a production process of a polymer optical waveguide that is Embodiment 6 of the present invention. FIG. 13 shows an example of the structure of the waveguide film manufactured by the manufacturing process of FIG. 12, FIG. 13 (a) is a top view of the waveguide film, and FIG. 13 (b) is the waveguide film. It is a side view. In these figures, the difference from the first embodiment is that the waveguide film 60 is produced by vertical cutting instead of the punching process. Note that, in these drawings, the substantially same members as those in the first embodiment are denoted by the same member names and symbols.

  Even in the production process of the polymer optical waveguide of Example 6, as shown in FIG. 13A, as in the production technique of the master, the mold, the auxiliary mold, and the long hole film in Example 1 above. The master, the mold 10, the auxiliary mold 20, and the film material 30 can be manufactured. In the production of the waveguide of Example 6, as shown in FIG. 13D, the waveguide film 60 is obtained by cutting a dicing saw using a vertical cutting blade instead of the punching process after the upper clad is produced. Each of the outer shape and the length of the waveguide core 61 is cut into two equal parts, and the waveguide length is formed to be 40 mm.

  Even in the manufacturing process of the polymer optical waveguide of Example 6, as shown in FIGS. 13A to 13D, the mold 10, the auxiliary mold 20 and the film material 30 in Example 1 are prepared. It is possible to produce a high-quality waveguide film 60 shown in FIG. Thereby, the waveguide film 60 which can connect a VCSEL or PD mounted on a plane and an optical fiber can be formed. The insertion loss from the VCSEL to the optical fiber is 1.5 dB or less, and high quality performance can be exhibited.

  The method for producing a polymer optical waveguide according to the present invention is not limited to the above-described embodiments, examples, and illustrated examples, and various design changes can be made without departing from the spirit of the invention. is there.

(A)-(d) is explanatory drawing which shows notionally the preparation procedure of the polymer optical waveguide which is Example 1 in this invention. (A), (b) is the top view and side view which show schematically the example of 1 structure of the waveguide film manufactured by the preparation procedure of FIG. (A)-(d) is explanatory drawing which shows notionally the preparation procedure of the polymer optical waveguide which is Example 2 in this invention. (A), (b) is the top view and side view which show schematically the example of 1 structure of the waveguide film manufactured by the preparation procedure of FIG. (A)-(c) is explanatory drawing which shows notionally the preparation procedure of the polymer optical waveguide which is Example 3 in this invention. (A), (b) is the top view and side view which show schematically the example of 1 structure of the waveguide film manufactured by the preparation procedure of FIG. (A)-(c) is explanatory drawing which shows notionally the preparation procedure of the polymer optical waveguide which is Example 4 in this invention. (A), (b) is the top view and side view which show schematically the example of 1 structure of the waveguide film manufactured by the preparation procedure of FIG. It is explanatory drawing for demonstrating the mounting form of the waveguide film of FIG. (A)-(c) is explanatory drawing which shows notionally the preparation procedure of the polymer optical waveguide which is Example 5 in this invention. (A), (b) is the top view and side view which show roughly the example of 1 structure of the waveguide film manufactured by the preparation procedure of FIG. (A)-(d) is explanatory drawing which shows notionally the preparation procedure of the polymer optical waveguide which is Example 6 in this invention. (A), (b) is the top view and side view which show roughly the example of 1 structure of the waveguide film manufactured by the preparation procedure of FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Mold 11 Groove part 20 Auxiliary mold 21 Resin filling port 22 Resin suction port 23 Parting surface 24, 25 Depression 30 Film material 31 Long hole 40 Metal mask 41 Through long hole 42 Deposition source 50, 70 UV curable resin 60 Waveguide film 61 Waveguide core 62 45-degree mirror surface 63 Cylindrical microlens 64 Spherical microlens 80 Film 90 VCSEL

Claims (8)

Using a mold having a concave groove corresponding to the pattern shape of the waveguide core;
Excluding both end portions of the concave groove portion, closely adhering a film material serving as a lower clad to the molding surface side of the mold,
Dropping a curable resin for forming a waveguide core into one end of the groove, suctioning the pressure through the other end of the groove, and filling the curable resin in the groove, and After the curing of the curable resin, the mold is peeled off from the film material, and the film material and a waveguide core having a form corresponding to the end portion are integrally formed. Manufacturing method of molecular optical waveguide. In addition to having a resin filling port for filling the curable resin in a portion corresponding to one end portion of the concave groove portion, a resin suction port for sucking the curable resin under reduced pressure in a portion corresponding to the other end portion of the concave groove portion Using auxiliary molds,
The auxiliary mold and the mold are brought into close contact with each other through the film material, and the curable resin is filled through the resin filling port and the resin suction port. The method for producing a polymer optical waveguide according to claim 1.   3. The method of manufacturing a polymer optical waveguide according to claim 2, wherein the auxiliary mold includes using a mold structure that presses an outer peripheral portion of the film material and adheres to the mold.   3. The method of manufacturing a polymer optical waveguide according to claim 2, wherein the auxiliary mold uses a mold structure having a microlens shape at a portion corresponding to an end portion of the concave groove portion. The mold uses a mold structure in which a plurality of the recessed groove portions are formed in parallel at a predetermined interval,
The said film material comprises using the film material which formed the long hole penetrated up and down in the site | part which cross | intersects the edge part of the said several groove part. A method for producing a polymer optical waveguide.   2. The mold according to claim 1, wherein the concave end surface of the concave groove portion uses a mold structure having a mirror shape that folds light propagating through the waveguide core in the direction of the film material. , 2 or 5, A method for producing a polymer optical waveguide. 7. A method comprising: depositing a metal thin film on a mirror-shaped portion of the waveguide core; and covering the entire surface of the waveguide core with a curable resin serving as an upper clad. The manufacturing method of the polymer optical waveguide of description.   3. The method for producing a polymer optical waveguide according to claim 1, further comprising stamping an outer peripheral portion of the polymer optical waveguide.

Images