Optical connection assembly and method for manufacturing optical connection assembly

Abstract

The invention provides an optical connection assembly and a manufacturing method of the optical connection assembly. An optical connection assembly is provided with: an arrangement conversion member in which a plurality of optical waveguides are arranged in a first direction on a first end surface, an optical waveguide array is formed from two or more optical waveguides arranged in the first direction on a second end surface, and the optical waveguide array is arranged in N stages in a second direction; and an optical connection member having two or more optical fiber arrays, each of the two or more optical fiber arrays including: two or more optical fibers connected to the two or more optical waveguides, respectively; and a holding member that arranges the two or more optical fibers in the first direction, the two or more optical fiber arrays being arranged in N stages in the second direction, each of the central axes of the two or more optical fibers included in the nth-stage optical fiber array and each of the central axes of the two or more optical fibers included in the corresponding (n-1) th-stage optical fiber array are offset in the first direction.

Description

Technical Field

[0001] This disclosure relates to optical connectivity components and methods for manufacturing optical connectivity components. Background Technology

[0002] For example, Patent Document 1 discloses an arrangement transformation component that modulates the spacing between multiple waveguides. Using such an arrangement transformation component, two optical components (e.g., a chip component and an optical fiber) with different spacing between waveguides can be connected with low loss.

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: International Publication No. 2018 / 135411

[0006] In recent years, with the increasing traffic volume of communication networks, there is a growing demand for higher density transmission paths. To achieve this, one approach is to use an arrangement conversion component as described above to connect multiple optical fibers to multiple waveguides of a chip component arranged with a narrower spacing. However, this configuration presents a problem: the more optical fibers are used, the wider the fiber spacing becomes, resulting in a larger overall width of the product, including the arrangement conversion component and the multiple optical fibers. Summary of the Invention

[0007] The problem that the invention aims to solve

[0008] This disclosure provides an optical connector assembly and a method for manufacturing the optical connector assembly that achieves both high density of transmission paths and miniaturization.

[0009] Solution for solving the problem

[0010] The optical connection component disclosed herein includes: an arrangement transformation component including a first end face, a second end face facing opposite to the first end face, and a plurality of optical waveguides extending from the first end face to the second end face, wherein the plurality of optical waveguides are arranged in a first direction in the first end face, and an optical waveguide array is formed by two or more optical waveguides arranged in the first direction in the second end face, wherein the optical waveguide array is configured in N orders (where N is an integer greater than or equal to 2) in a second direction intersecting the first direction; and an optical connection component having two or more fiber arrays, each of the two or more fiber arrays including: two or more optical fibers respectively connected to two or more optical waveguides; and a holding component for arranging the two or more optical fibers in the first direction, wherein the two or more fiber arrays are configured in N orders in the second direction, and each of the central axes of the two or more optical fibers included in the nth order (where n is an integer greater than or equal to 2 and less than N) fiber array is offset in the first direction from each of the central axes of the two or more optical fibers included in the corresponding (n-1)th order fiber array.

[0011] Invention Effects

[0012] According to the optical connection component and the manufacturing method of the optical connection component disclosed herein, it is possible to achieve miniaturization while increasing the density of the transmission path. Attached Figure Description

[0013] Figure 1 This is a perspective view of an optical connection component according to one embodiment.

[0014] Figure 2 It means Figure 1 A top view of the first end face of the arrangement transformation component of the optical connection assembly.

[0015] Figure 3 It means Figure 1 A top view of the second end face of the arrangement transformation component of the optical connection assembly.

[0016] Figure 4 It means Figure 1 The main view of the optical connection components of the optical connection assembly.

[0017] Figure 5 It means Figure 1 A three-dimensional diagram of the manufacturing process of optical connector components.

[0018] Figure 6 It means Figure 1 The main view of the configuration of the holding components during the manufacturing process.

[0019] Figure 7 It means Figure 5 A three-dimensional view of the subsequent manufacturing processes of the first manufacturing process.

[0020] Figure 8 It means Figure 7 The main view of the configuration of the holding components during the manufacturing process.

[0021] Figure 9 It means Figure 7 A three-dimensional view of the subsequent manufacturing processes of the first manufacturing process.

[0022] Figure 10 It means Figure 9 The main view of the configuration of the holding components during the manufacturing process.

[0023] Figure 11 It means Figure 9 A three-dimensional view of the subsequent manufacturing processes of the first manufacturing process.

[0024] Figure 12 It means Figure 11 The main view of the configuration of the holding components during the manufacturing process.

[0025] Figure 13 It means Figure 11 A three-dimensional view of the subsequent manufacturing processes of the first manufacturing process.

[0026] Figure 14 It means Figure 13 The main view of the configuration of the holding components during the manufacturing process.

[0027] Figure 15 It means Figure 13 A three-dimensional view of the subsequent manufacturing processes of the first manufacturing process.

[0028] Figure 16 It means Figure 15 The main view of the configuration of the holding components during the manufacturing process.

[0029] Figure 17 It means Figure 15 A three-dimensional view of the subsequent manufacturing processes of the first manufacturing process.

[0030] Figure 18 It means Figure 17 The main view of the configuration of the holding components during the manufacturing process.

[0031] Explanation of reference numerals in the attached figures:

[0032] 1: Optical connection component; 2: Connection object component; 3: Main surface; 5: Optical input / output section; 10: Arrangement transformation component; 11: First end face; 12: Second end face; 15: Optical waveguide; 15A, 15B: Optical waveguide array; 15a: First end; 15b: Second end; 20: Optical connection component; 20a: First end; 20b: Second end; 23: Optical fiber; 23a: Fiber core; 23b: Glass fiber; 25: Holding component; 25a: Lower end face; 25b: Top face; 25c: Front face; 25d: Side face; 25A: Fiber array; 26: Support; 26a: V-groove; 27: Cover; 30: Core alignment component; 31: Cover; 32: Support; 33: Core alignment fiber; 40: Gripping component; 40a, 40b: Gripping components; C: Central axis; d1, d2, d3: Misalignment; D: Dummy fiber; D25: Outer diameter; P: Protruding part; p11, p12, p21: Spacing. Detailed Implementation

[0033] [Description of embodiments of this disclosure]

[0034] First, the contents of the embodiments of this disclosure will be described.

[0035] (1) The optical connection component of the present disclosure comprises: an arrangement transformation component including: a first end face, a second end face facing opposite to the first end face, and a plurality of optical waveguides extending from the first end face to the second end face, wherein the plurality of optical waveguides are arranged in a first direction in the first end face, and an optical waveguide array is formed by two or more optical waveguides arranged in the first direction in the second end face, wherein the optical waveguide array is configured in N orders (where N is an integer greater than or equal to 2) in a second direction intersecting the first direction; and an optical connection component having two or more fiber arrays, each of the two or more fiber arrays comprising: two or more optical fibers respectively connected to two or more optical waveguides; and a holding component for arranging the two or more optical fibers in the first direction, wherein the two or more fiber arrays are configured in N orders in the second direction, and each of the central axes of the two or more optical fibers included in the nth order (where n is an integer greater than or equal to 2 and less than N) fiber array is offset in the first direction from each of the central axes of the two or more optical fibers included in the corresponding (n-1)th order fiber array.

[0036] The aforementioned optical connection assembly comprises two or more fiber arrays, each including two or more optical fibers and a holding member arranging the two or more optical fibers in a first direction, configured as N-level optical connection components. With the fiber arrays configured as N-level, multiple optical fibers are arranged in both the first and second directions, thus reducing the width of the optical connection component in the first direction compared to the case where multiple optical fibers are arranged only in the first direction. Furthermore, in the aforementioned optical connection assembly, the central axes of each of the two or more optical fibers included in the nth-level fiber array are offset from the central axes of each of the two or more optical fibers included in the corresponding (n-1)th-level fiber array in the first direction. In this case, by arranging the optical fibers in an interleaved manner, a higher density of optical fibers can be arranged in the first direction. As a result, even if the spacing between the optical input / output portions of the connection target component connected to each optical waveguide in the first end face is further narrowed, each optical fiber can be arranged with a high density corresponding to the spacing of each optical input / output portion. Therefore, without complicating the paths of the optical waveguides of the arrangement conversion member, each optical fiber of the optical connection component can be connected to each optical input / output portion of the connection target component with high density. Therefore, based on the above-mentioned optical connection component, it is possible to achieve high density of transmission paths between the optical connection component and the connected component while miniaturizing the optical connection component.

[0037] (2) In the optical connection assembly described in (1) above, the offset in the first direction between the central axis of each of the two or more optical fibers included in the nth-level optical fiber array and the central axis of each of the two or more optical fibers included in the (n-1)th-level optical fiber array is less than the outer diameter of the optical fiber. In this case, the optical fibers can be arranged at a higher density in the first direction, thus further increasing the density of the transmission path between the optical connection component and the connected component.

[0038] (3) In the optical connection assembly described in (1) or (2) above, the spacing between the plurality of optical waveguides arranged adjacent to each other in the second direction on the second end face in the first direction may be the same as the spacing between the plurality of optical waveguides in the first end face in the first direction. In this case, each optical waveguide of the arrangement transformation component can be formed as a planar waveguide with a two-dimensional variation inside the arrangement transformation component. Therefore, compared with the case where a three-dimensional optical waveguide is formed inside the arrangement transformation component, the width of the arrangement transformation component in the first direction can be further reduced while suppressing the complexity of the paths of each optical waveguide. As a result, the optical connection assembly can be miniaturized more reliably.

[0039] (4) In any of the optical connection assemblies described in (1) to (3) above, two or more fiber arrays may be configured side-by-side in the first direction. When the fiber array includes more fibers, the fiber array becomes longer in the first direction depending on the number of fibers. Even in this case, according to the above configuration, it is not necessary to prepare new holding members of a length corresponding to the number of fibers; by combining existing multiple holding members, a fiber array including two or more fibers arranged in the first direction can be formed. Therefore, according to the above configuration, an optical connection assembly can be manufactured at low cost using existing holding members.

[0040] (5) In the optical connection assembly described in (4) above, the nth-level fiber array in two or more fiber arrays may be staggered in the first direction from the adjacent (n-1)th-level fiber array in the second direction. In this staggered configuration of the fiber arrays, the staggered portion of the fiber arrays is gripped by the gripping member, thereby avoiding interference of the gripping member with the fiber arrays of different levels and facilitating the positioning of the fiber and the optical waveguide of the arrangement conversion component of the fiber array.

[0041] (6) The method for manufacturing the optical connection component disclosed herein comprises: a preparation step, preparing an arrangement transformation component and two or more optical fiber arrays, the arrangement transformation component including a first end face, a second end face different from the first end face, and a plurality of optical waveguides extending from the first end face to the second end face, the plurality of optical waveguides being arranged in a first direction in the first end face, and an optical waveguide array being formed by the two or more optical waveguides arranged in the first direction in the second end face, wherein the optical waveguide array is configured in N orders (where N is an integer greater than or equal to 2) in a second direction intersecting the first direction, and the two or more optical fiber arrays each including: two or more optical fibers; and a holding component for arranging the two or more optical fibers in the first direction; and an alignment step, wherein at a position facing the second end face, the optical fiber array of the nth order (where n is an integer greater than or equal to 2 and less than N) is held by a gripping component. In the state of the array, two or more optical fibers included in the nth-level fiber array are positioned relative to two or more optical waveguides of the nth level; and in the connection process, while the two or more optical fibers included in the nth-level fiber array are positioned relative to the two or more optical waveguides of the nth level, the fiber array is fixed to the second end face, thereby connecting the two or more optical fibers included in the nth-level fiber array to the two or more optical waveguides of the nth level. The core alignment process and the connection process are repeatedly performed in each level up to the Nth level, thereby arranging the fiber array into N levels in the second direction such that the central axis of each of the two or more optical fibers included in the nth-level fiber array is offset from the central axis of each of the two or more optical fibers included in the corresponding (n-1)th-level fiber array in the first direction, thereby forming an optical connection component having an N-level fiber array. According to the manufacturing method of this optical connection component, as described above, it is possible to achieve high density of transmission paths between the optical connection component and the connected component while miniaturizing the optical connection component.

[0042] (7) In the manufacturing method of the optical connector assembly described in (6) above, in the preparation step, two or more fiber arrays configured to be arranged side by side in the first direction are prepared. In the alignment step, with the nth-level fiber array held by a gripper in a state where the nth-level fiber array is held in a way that the (n-1)th-level fiber array adjacent to the nth-level fiber array in the second direction is staggered in the first direction, the two or more fibers included in the nth-level fiber array are positioned relative to two or more optical waveguides. In this case, even if the fiber array becomes longer in the first direction according to the number of fibers, it is not necessary to prepare a new holding member of a length corresponding to the number of fibers. By combining multiple existing holding members, a fiber array including two or more fibers arranged in the first direction can be formed. Therefore, according to the above configuration, an optical connector assembly can be manufactured at low cost using existing holding members. Furthermore, when the fiber arrays are configured in a staggered manner as described above, the staggered portions of the fiber arrays can be gripped by the gripping members, thereby avoiding interference of the gripping members with different levels of fiber arrays and easily positioning the optical fibers of the fiber arrays and the optical waveguides of the arrangement conversion components.

[0043] (8) In the manufacturing method of the optical connection component described in (7) above, it is also possible to designate the first fiber array at the first end of the optical connection component in the first direction as the first, the second fiber array at the second end of the optical connection component in the first direction as the Mth (where M is an integer greater than or equal to 2), and the fiber array with the smallest offset from the (m-1)th fiber array to the second end in the first direction as the mth (where m is an integer greater than or equal to 2 and less than or equal to M), and repeatedly perform the alignment and connection processes by holding the fiber arrays from the first to the Mth in this order by the gripper, and by holding the protruding portion of the mth fiber array that protrudes from the second end in the first direction relative to the fiber array adjacent to the mth fiber array in the second direction by the gripper in the second direction. By repeatedly performing the alignment and connection processes from the first to the Mth fiber arrays by holding the protruding portion of the fiber arrays in the second direction by the gripper in the second direction, interference between the gripper holding the fiber arrays and fiber arrays of different levels can be more reliably avoided. This makes it easier to position the optical fibers and waveguides of the fiber array's arrangement transformation components.

[0044] [Details of the embodiments of this disclosure]

[0045] The following detailed description, with reference to the accompanying drawings, illustrates specific examples of the optical connection components and methods for manufacturing the optical connection components of this disclosure. The invention is not limited to these examples, but is shown in the claims, which are intended to include all modifications within the meaning and scope equivalent to the claims. In the description of the drawings, the same reference numerals are used to denote the same elements, and repeated descriptions are omitted where appropriate.

[0046] like Figure 1 As shown, the optical connection assembly 1 includes an arrangement transformation component 10 and an optical connection component 20. For ease of understanding, Figure 1 The diagram shows an XYZ Cartesian coordinate system. The X direction (first direction), Y direction (second direction), and Z direction intersect each other (e.g., orthogonal). The arrangement transformation component 10 is, for example, cuboid in shape, including a first end face 11, a second end face 12 facing opposite to the first end face 11, and a plurality of optical waveguides 15 extending from the first end face 11 to the second end face 12.

[0047] The first end face 11 and the second end face 12 are, for example, planes extending along the X and Y directions respectively, and side by side along the Z direction. In one example, the first end face 11 and the second end face 12 are parallel to each other, and the normal directions of the first end face 11 and the second end face 12 are aligned with each other. The first end 15a of each of the plurality of optical waveguides 15 is located on the first end face 11. The second end 15b of each of the plurality of optical waveguides 15 is located on the second end face 12. The arrangement of the first ends 15a of each optical waveguide 15 in the first end face 11 is different from the arrangement of the second ends 15b of each optical waveguide 15 in the second end face 12. The arrangement transformation unit 10 transforms the arrangement of the first ends 15a of each optical waveguide 15 to the arrangement of the second ends 15b of each optical waveguide 15.

[0048] like Figure 2 As shown, the first ends 15a of each optical waveguide 15 are arranged in a row along the X direction in the first end face 11. The first ends 15a of each optical waveguide 15 are arranged at equal intervals along the X direction, for example. The spacing p11 of the first ends 15a of each optical waveguide 15 in the X direction is, for example, less than 80 μm. The spacing p11 of the first ends 15a of each optical waveguide 15 in the X direction refers to the distance between the centers of the first ends 15a of two adjacent optical waveguides 15 in the X direction. The first ends 15a of multiple optical waveguides 15 arranged in a row along the X direction form an optical waveguide array 15A. The optical waveguide array 15A can also be configured in two or more stages in the Y direction.

[0049] like Figure 3As shown, the second ends 15b of each optical waveguide 15 are arranged along the X and Y directions in the second end face 12. Two or more optical waveguides 15 arranged in a row along the X direction form an optical waveguide array 15B. The optical waveguide array 15B is configured in N levels along the Y direction (where N is an integer greater than or equal to 2). In this embodiment, a three-level (N=3) optical waveguide array 15B is formed along the Y direction. The number of levels in the optical waveguide array 15B is not limited to three levels; it can also be two levels or more.

[0050] The optical waveguides 15 forming the optical waveguide array 15B are arranged at equal intervals along the X direction, for example. The spacing p12 between the second ends 15b of each optical waveguide 15 in the X direction is, for example, 80 μm or more. The spacing p12 between the second ends 15b of each optical waveguide 15 can be 125 μm or more, or it can be 250 μm or more. The spacing p12 between the second ends 15b of each optical waveguide 15 refers to the distance between the centers of the second ends 15b of two adjacent optical waveguides 15 in the X direction in the optical waveguide array 15B.

[0051] The centers of each optical waveguide 15 in the nth-level (where n is an integer greater than 2 and less than N) optical waveguide array 15B of N levels are configured to be offset in the X direction relative to the centers of each optical waveguide 15 in the (n-1)th-level optical waveguide array 15B. That is, the centers of each optical waveguide 15 in the nth-level are configured to be staggered with the centers of each optical waveguide 15 in the (n-1)th-level in the X direction. In one example, the centers of all optical waveguides 15 in the second level and above are configured to be offset in the X direction relative to the centers of each optical waveguide 15 in the first level.

[0052] The offset d1 of the nth-order optical waveguide 15 relative to the (n-1)th-order optical waveguide 15 in the X direction is less than the spacing p12 of the second ends 15b of each optical waveguide 15 in the X direction. The offset d1 of the nth-order optical waveguide 15 relative to the (n-1)th-order optical waveguide 15 is the distance in the X direction between the centers of the nth-order optical waveguide 15 and the centers of the (n-1)th-order optical waveguide 15. The offset d1 is equivalent to the spacing in the X direction between each optical waveguide 15 adjacent to each other in the Y direction. The spacing in the X direction between each optical waveguide 15 adjacent to each other in the Y direction (i.e., the offset d1) is, for example, the same as the spacing p11 of the first ends 15a of each optical waveguide 15 in the X direction. In this case, each optical waveguide 15 extending from the first end face 11 to the second end face 12 forms a two-dimensional planar waveguide extending along the Y and Z directions. The path of each optical waveguide 15 forming the planar waveguide does not change in the X direction but changes in the plane along the Y and Z directions.

[0053] like Figure 4As shown, the optical connector 20 includes a plurality of optical fibers 23 and a plurality of retaining members 25. The plurality of optical fibers 23 may be, for example, single-core optical fibers, but may also be multi-core optical fibers or other types of optical fibers. In the case where each optical fiber 23 is a single-core optical fiber, each optical fiber 23 includes a glass fiber 23b having a core 23a on its central axis C. The glass fiber 23b is surrounded by a resin coating. The tip of the glass fiber 23b protrudes from the resin coating. The outer diameter of the glass fiber 23b is, for example, 125 μm. The outer diameter of the resin coating surrounding the glass fiber 23b is, for example, 250 μm. The outer diameter of the glass fiber 23b corresponds to the outer diameter D25 of the optical fiber 23 held by the retaining members 25.

[0054] Multiple optical fibers 23 are arranged along the X and Y directions in a manner corresponding to the arrangement of the second ends 15b of each optical waveguide 15 described above. Two or more optical fibers 23 arranged in a row along the X direction and a holding member 25 holding the two or more optical fibers 23 arranged in a row along the X direction form an optical fiber array 25A. That is, the optical fiber array 25A includes: two or more optical fibers 23; and a holding member 25 that arranges the two or more optical fibers 23 in a row along the X direction. The optical fiber array 25A is arranged in a row along the X direction. The optical fiber array 25A is configured in N stages along the Y direction. In this embodiment, a three-stage (N=3) optical fiber array 25A is formed along the Y direction. The number of stages in the optical fiber array 25A is not limited to three stages; it can also be two stages, or even four stages or more. The optical fiber array 25A can also be an optical fiber array in which a single optical fiber 23 is disposed within the holding member 25. That is, the optical fiber array 25A can also include a single optical fiber 23 and a holding member holding the single optical fiber 23.

[0055] The optical fibers 23 forming the optical fiber array 25A are arranged at equal intervals along the X direction, for example. The spacing p21 of the optical fibers 23 in the X direction is, for example, 80 μm or more. The spacing p21 of the optical fibers 23 and the spacing p12 of the second end 15b of each optical waveguide 15 (refer to...) Figure 3 The spacing p21 between each fiber 23 can be, for example, 125 μm or more, or 250 μm or more. The spacing p21 between each fiber 23 refers to the distance between the central axes C of two adjacent fibers 23 in the X direction in the fiber array 25A.

[0056] The central axis C of each fiber 23 in the nth-level fiber array 25A is configured to be offset in the X direction from the central axis C of each fiber 23 in the corresponding (n-1)th-level fiber array 25A. That is, the central axis C of each fiber 23 in the nth-level is configured to be staggered in the X direction from the central axis C of each fiber 23 in the corresponding (n-1)th-level. The (n-1)th-level fiber 23 corresponding to the nth-level fiber 23 refers to the (n-1)th-level fiber 23 with the smallest offset d2 in the X direction relative to the nth-level fiber 23. In one example, the central axis C of all fibers 23 above the second level is configured to be offset in the X direction from the central axis C of the first-level fibers 23. The offset d2 of the nth-level fiber 23 relative to the (n-1)th-level fiber 23 in the X direction is equivalent to the spacing (e.g., the distance between central axes C) of adjacent fibers 23 in the Y direction. The offset d2 is less than the spacing p21 of each fiber 23 in the nth order, for example, less than the outer diameter D25 of the glass fiber 23b. For example, the offset d2 (i.e., the spacing of each fiber 23 adjacent to each other in the Y direction in the X direction) is, for example, the spacing p11 of the first end 15a of each optical waveguide 15 in the X direction (refer to...). Figure 2 )same.

[0057] A holding member 25 forming an optical fiber array 25A includes: a support portion 26 supporting two or more optical fibers 23; and a cover portion 27 covering the support portion 26 across two or more optical fibers 23. For example, glass fibers 23b of two or more optical fibers 23 are placed in two or more V-grooves 26a formed in the support portion 26, and the cover portion 27 is configured to cover the two or more glass fibers 23b. In addition to the holding member 25 in which optical fibers 23 are placed in all V-grooves 26a, the optical fiber array 25A also includes a holding member 25 in which optical fibers 23 and dummy optical fibers D that do not contribute to light guiding are placed in the V-grooves 26a of the holding member 25. Dummy optical fibers D may not necessarily be placed in the V-grooves 26a of the holding member 25. That is, optical fibers 23 that contribute to light guiding may also be placed in all V-grooves 26a of the holding member 25. The bottom surface of the support portion 26 forms the lower end surface 25a of the holding member 25. The top surface of the cover portion 27 forms the upper end surface 25b of the holding member 25. The front end faces of the support portion 26 and the cover portion 27 respectively form the front end face 25c of the retaining member 25. The lower end face 25a is the end face of the first end of the retaining member 25 located in the Y direction. The upper end face 25b is the end face of the second end of the retaining member 25 located in the Y direction. The front end face 25c is the end face of the end of the retaining member 25 located in the Z direction.

[0058] The nth-level fiber array 25A is configured to be offset in the X direction from the (n-1)th-level fiber array 25A adjacent to it in the Y direction. Specifically, the holding member 25 of the nth-level fiber array 25A is configured to be offset in the X direction from the holding member 25 of the (n-1)th-level fiber array 25A adjacent to it in the Y direction. That is, the side end face 25d of the holding member 25 of each nth-level fiber array 25A in the X direction protrudes or is recessed in the X direction relative to the side end face 25d of the holding member 25 of each (n-1)th-level fiber array 25A. Figure 4 The diagram shows the offset d3 of the nth-level fiber array 25A relative to the (n-1)th-level fiber array 25A. The offset d3 is the distance in the X-direction between the side end face 25d of the holding member 25 of the (n-1)th-level fiber array 25A and the side end face 25d of the holding member 25 of the nth-level fiber array 25A. The boundary positions of two adjacent fiber arrays 25A in the X-direction are configured to be offset in the X-direction within each level. For example, this boundary position is the center position of the gap between two adjacent holding members 25 in the X-direction.

[0059] Refer again Figure 1 .like Figure 1 As shown, each fiber array 25A is configured such that its front end face 25c faces the second end face 12 of the arrangement conversion member 10. The optical fiber 23 included in each fiber array 25A is configured to face the second end 15b of the optical waveguide 15 in the second end face 12 and is connected to the optical waveguide 15. The holding member 25 of the fiber array 25A and the optical fiber 23 are fixed to the second end face 12, for example, by a UV-curable adhesive. A connection object member 2, serving as the connection object of the optical connection member 20, is disposed on the first end face 11 of the arrangement conversion member 10. Figure 1 The optical connection component 20 and the connection target component 2 are shown to be arranged in the arrangement transformation component 10 with a slight gap between them, but the optical connection component 20 and the connection target component 2 can also be in contact with the arrangement transformation component 10 without gap.

[0060] The connecting component 2 is, for example, a chip component such as a silicon photonics chip. The connecting component 2 includes, for example, a main surface 3 on which multiple optical input / output sections 5 are mounted. The main surface 3 is, for example, a plane extending along the X direction, configured to face the first end surface 11 of the arrangement transformation component 10. Each optical input / output section 5 is arranged side-by-side in the X direction on the main surface 3, and each optical input / output section 5 is configured to face the first end 15a of each optical waveguide 15 in the first end surface 11 and connected to each optical waveguide 15. The spacing between the optical input / output sections 5 in the X direction and the spacing p11 between the first ends 15a of each optical waveguide 15 in the X direction (refer to...) Figure 2 The same, for example, less than 80 μm. The spacing between each optical input / output section 5 in the X direction refers to the distance between the centers of two adjacent optical input / output sections 5 in the X direction.

[0061] Reference Figures 5 to 18 The manufacturing method of the optical connection component 1 in this embodiment will be described.

[0062] First, in addition to preparing the aforementioned arrangement transformation component 10 and optical connection component 20, also prepare... Figure 5 The alignment component 30 shown is a preparatory step. The alignment component 30 is a component used to determine the position of the optical fiber 23 of the optical connector 20 relative to the optical waveguide 15 of the alignment conversion component 10. The alignment component 30 includes a plurality of alignment optical fibers 33, a cover portion 31, and a support portion 32. Each alignment optical fiber 33 is spaced at a distance p11 greater than the distance p11 between the first ends 15a of each optical waveguide 15 in the first end face 11 (see reference). Figure 2 The large-pitched optical fibers 33 are arranged in a row along the X direction. Each fiber 33 is supported by a support portion 32 and covered by a cover portion 31.

[0063] The alignment member 30 is configured to face the first end face 11 of the alignment conversion member 10. The fiber array 25A of the optical connection member 20 is configured to face the second end face 12 of the alignment conversion member 10. The fiber array 25A includes one or more optical fibers 23. The fiber array 25A is held in place by the gripping member 40 (see reference). Figure 6 In the grasped state, the fiber 23 faces the second end face 12. The fiber 23 included in the fiber array 25A is configured to face the second end 15b of the optical waveguide 15 of the second end face 12 and is positioned (aligned) relative to the optical waveguide 15 (aligning process). Then, the fiber array 25A (specifically, the holding member 25 that holds the fiber 23) is fixed to the alignment transformation member 10 by adhesive, and the fiber 23 is connected to the optical waveguide 15 of the alignment transformation member 10 (connection process).

[0064] The above-described alignment and connection processes are repeated for each holding member 25. For example, if the fiber array 25A at the first end 20a of the optical connection member 20 in the X direction is designated as the first, the fiber array 25A at the second end 20b of the optical connection member 20 in the X direction is designated as the Mth (where M is an integer greater than or equal to 2), and the fiber array 25A with the smallest offset d3 relative to the (m-1)th fiber array 25A in the X direction at the second end 20b is designated as the mth (where m is an integer greater than or equal to 2 and less than or equal to M), the alignment and connection processes are repeated for each fiber array 25A in this order, from the first fiber array 25A to the Mth fiber array 25A, by being held by the gripper 40 (see reference). Figure 4 ).

[0065] The m-th fiber array 25A is a fiber array 25A of a different level from the (m-1)-th fiber array 25A and is positioned adjacent to the (m-1)-th fiber array 25A in the Y direction. The offset d3 of the m-th fiber array 25A relative to the (m-1)-th fiber array 25A refers to the distance in the X direction between the side end face 25d of the holding member 25 of the (m-1)-th fiber array 25A and the side end face 25d of the holding member 25 of the m-th fiber array 25A.

[0066] The manufacturing method of the optical connector 1, including the alignment process and the connection process, will be described in more detail below.

[0067] First, such as Figure 5 and Figure 6 As shown, a first fiber array 25A is arranged on the second end face 12 of the arrangement transformation component 10. Then, with the alignment component 30 spaced apart in the Z direction relative to the first end face 11, image processing is used, for example, to roughly position the alignment fiber 33 relative to the optical waveguide 15, which is the connection object of the fiber 23 included in the first fiber array 25A (coarse alignment).

[0068] Next, the first fiber array 25A, held by the gripper 40, is positioned with a gap in the Z direction relative to the second end face 12. In this state, for example, image processing is used to roughly position (coarse core alignment) the optical fibers 23 included in the first fiber array 25A relative to the optical waveguide 15 to which they are connected. The first fiber array 25A may be located in the second stage (n=2), but it may also be located in the first stage or the third stage (n=3). Here, Figure 6 The gripper 40 shown is, for example, a chuck, which includes a pair of gripping portions 40a and 40b that clamp the fiber array 25A in the Y direction. The gripping portion 40a contacts the lower end face 25a of the holding member 25 of the fiber array 25A, and the gripping portion 40b contacts the upper end face 25b of the holding member 25 of the fiber array 25A.

[0069] Next, the alignment fiber 33, optical waveguide 15, and optical fiber 23 are precisely positioned relative to each other. For example, measurement light is incident on the alignment fiber 33, optical waveguide 15, and optical fiber 23. Then, to maximize the coupling efficiency of the measurement light, the positions of the alignment fiber 33, optical waveguide 15, and optical fiber 23 are adjusted using a three-body alignment (peak search alignment). Thus, the alignment fiber 33, optical waveguide 15, and optical fiber 23 are positioned relative to each other with high precision.

[0070] Next, the first fiber array 25A is temporarily retracted, and a predetermined amount of UV-curable adhesive is applied to the second end face 12. Afterward, the first fiber array 25A returns to its original position (i.e., the position after high-precision positioning). At this time, the adhesive is evenly distributed between the second end face 12 and the fiber array 25A. Then, the adhesive is irradiated with UV light for a predetermined time, thereby curing the adhesive. Thus, the first fiber array 25A is fixed to the second end face 12, and the optical fibers 23 of the first fiber array 25A are connected to the optical waveguide 15 of the connected object. Afterward, the first fiber array 25A fixed to the second end face 12 is released from the gripper 40.

[0071] Next, as Figure 7 and Figure 8 As shown, a second fiber array 25A is configured on the second end face 12 of the arrangement transformation component 10. The second fiber array 25A is configured, for example, as the first stage in an N-stage configuration. Therefore, the second fiber array 25A is configured as a different stage from the first fiber array 25A. The second fiber array 25A is adjacent to the first fiber array 25A in the Y direction, with its second end 20b (refer to) in the X direction relative to the first fiber array 25A. Figure 4 The prominent features are staggered.

[0072] With the alignment component 30 spaced apart in the Z direction relative to the first end face 11, image processing is used, for example, to roughly position the two alignment optical fibers 33 relative to the two optical waveguides 15 that are the connection objects of the two optical fibers 23 included in the second optical fiber array 25A (coarse alignment).

[0073] Next, the second fiber array 25A, held by the gripper 40, is positioned at a location with a gap in the Z direction relative to the second end face 12. For example... Figure 8 As shown, the gripper 40 grips the protruding portion P of the second fiber array 25A in the Y direction, which protrudes in the X direction relative to the first fiber array 25A. The thickness T40 of each gripper portion 40a and gripper portion 40b in the Y direction is less than or equal to the thickness T25 of the holding member 25 in the Y direction. With the second fiber array 25A gripped by the gripper 40, image processing is used, for example, to roughly position (coarsely align) the two optical fibers 23 held in the second fiber array 25A relative to the two optical waveguides 15 that are to be connected.

[0074] Next, the two alignment fibers 33, the two optical waveguides 15, and the fiber 23 are precisely positioned relative to each other. For example, measurement light is incident on the first alignment fiber 33 of the two alignment fibers 33, the first optical waveguide 15 of the two optical waveguides 15, and the first fiber 23 of the two fibers 23. Then, to maximize the coupling efficiency of the measurement light, three-body alignment (peak search alignment) is performed on the first alignment fiber 33, the first optical waveguide 15, and the first fiber 23. As a result, the first alignment fiber 33, the first optical waveguide 15, and the first fiber 23 are precisely positioned relative to each other. At this time, the position of the first fiber 23 relative to the alignment conversion unit 10 is recorded.

[0075] Next, measurement light is incident on the second optical fiber 33 of the two optical fibers 33, the second optical waveguide 15 of the two optical waveguides 15, and the second optical fiber 23 of the two optical fibers 23. Then, to maximize the coupling efficiency of the measurement light, three-body alignment (peak search alignment) is performed on the second optical fiber 33, the second optical waveguide 15, and the second optical fiber 23. As a result, the second optical fiber 33, the second optical waveguide 15, and the second optical fiber 23 are positioned relative to each other with high precision. At this time, the position of the second optical fiber 23 relative to the alignment conversion unit 10 is recorded.

[0076] Next, the recorded positions of the first fiber 23 and the second fiber 23 are compared, and the rotation amount of the fiber array 25A required to align these positions with the reference position is calculated. If this rotation amount is outside the allowable range, the peak search alignment described above is performed again. If the calculated rotation amount is within the allowable range, the second fiber array 25A is temporarily retracted, and a specified amount of UV-curable adhesive is applied to the second end face 12. Afterward, the second fiber array 25A returns to its original position (i.e., the position after being positioned with high precision).

[0077] At this point, the adhesive is evenly distributed between the second end face 12 and the fiber array 25A. Then, the adhesive is irradiated with ultraviolet light for a predetermined time, thereby curing the adhesive. As a result, the second fiber array 25A is fixed to the second end face 12, and each fiber 23 of the second fiber array 25A is connected to each optical waveguide 15 of the connected object. Afterward, the second fiber array 25A, fixed to the second end face 12, is released from the gripper 40.

[0078] Next, as Figure 9 and Figure 10As shown, a third fiber array 25A is arranged on the second end face 12 of the arrangement transformation component 10. The third fiber array 25A is configured, for example, as the third level in an N-level array (n=3). Therefore, the third fiber array 25A is configured as a different level from the second fiber array 25A. The third fiber array 25A is adjacent to the second fiber array 25A in the Y direction, with its second end 20b (refer to) in the X direction relative to the second fiber array 25A. Figure 4 The prominent features are staggered.

[0079] With the alignment component 30 spaced apart in the Z direction relative to the first end face 11, image processing is used, for example, to roughly position the three alignment optical fibers 33 relative to the three optical waveguides 15 that are the connection objects of the three optical fibers 23 included in the third optical fiber array 25A (coarse alignment).

[0080] Next, the third fiber array 25A, held by the gripper 40, is positioned at a location with a gap in the Z direction relative to the second end face 12. For example... Figure 10 As shown, the gripper 40 grips the protruding portion P of the third fiber array 25A in the Y direction, which protrudes in the X direction relative to the second fiber array 25A. With the third fiber array 25A gripped by the gripper 40, image processing is used, for example, to roughly position (coarse core alignment) the three optical fibers 23 included in the third fiber array 25A relative to the three optical waveguides 15 that are to be connected.

[0081] Next, the three alignment fibers 33, the three optical waveguides 15, and the fiber 23 are precisely positioned relative to each other. For example, measurement light is incident on the first alignment fiber 33 (located at its first end in the X direction), the first optical waveguide 15 (located at its first end in the X direction), and the first fiber 23 (located at its first end in the X direction). Then, to maximize the coupling efficiency of the measurement light, three-body alignment (peak search alignment) is performed on the first alignment fiber 33, the first optical waveguide 15, and the first fiber 23. As a result, the first alignment fiber 33, the first optical waveguide 15, and the first fiber 23 are precisely positioned relative to each other. At this time, the position of the first fiber 23 relative to the alignment conversion unit 10 is recorded.

[0082] Next, measurement light is incident on the second optical fiber 33 (located at its second end in the X direction) of the three optical fiber 33, the second optical waveguide 15 (located at its second end in the X direction) of the three optical waveguides 15, and the second optical fiber 23 (located at its second end in the X direction) of the three optical fibers 23. Then, to maximize the coupling efficiency of the measurement light, three-body alignment (peak search alignment) is performed on the second optical fiber 33, the second optical waveguide 15, and the second optical fiber 23. As a result, the second optical fiber 33, the second optical waveguide 15, and the second optical fiber 23 are positioned relative to each other with high precision. At this time, the position of the second optical fiber 23 relative to the alignment conversion unit 10 is recorded.

[0083] Next, the recorded positions of the first and second optical fibers 23 are compared, and the rotation amount of the fiber array 25A required to align these positions with the reference position is calculated. If this rotation amount is outside the allowable range, the peak search alignment described above is performed again. If the calculated rotation amount is within the allowable range, the third fiber array 25A is temporarily retracted, and a specified amount of UV-curable adhesive is applied to the second end face 12. Afterward, the third fiber array 25A returns to its original position (i.e., the position after high-precision positioning).

[0084] At this point, the adhesive is evenly distributed between the second end face 12 and the fiber array 25A. Then, the adhesive is irradiated with ultraviolet light for a predetermined time, thereby curing the adhesive. As a result, the third fiber array 25A is fixed to the second end face 12, and each fiber 23 of the third fiber array 25A is connected to each optical waveguide 15 of the connected object. Afterward, the third fiber array 25A fixed to the second end face 12 is released from the gripper 40.

[0085] For the fourth fiber array 25A (reference) Figure 11 and Figure 12 ), the fifth fiber array 25A (refer to Figure 13 and Figure 14 ), the sixth fiber array 25A (refer to Figure 15 and Figure 16 ) and the seventh fiber array 25A (refer to Figure 17 and Figure 18 The alignment and connection processes are performed in this order. In each fiber array 25A, its protruding portion P is held in the Y direction by the gripper 40, and the alignment and connection processes are performed in this state. After the above processes, all fiber arrays 25A are connected to the optical connection assembly 1 of the arrangement conversion component 10.

[0086] The effects obtained by the optical connection component 1 and the manufacturing method of the optical connection component 1 according to this embodiment will be explained.

[0087] The optical connection assembly 1 of this embodiment includes an optical connection member 20 in which the fiber array 25A is configured in N-level arrays. With the fiber array 25A configured in N-level arrays, multiple optical fibers 23 are arranged in both the X and Y directions. Therefore, compared to the case where the multiple optical fibers 23 are arranged only in the X direction, the width of the optical connection member 20 in the X direction can be reduced. Furthermore, in the optical connection assembly 1 of this embodiment, the central axis C of each optical fiber 23 included in the nth-level fiber array 25A is offset in the X direction from the central axis C of each optical fiber 23 included in the corresponding (n-1)th-level fiber array 25A. In this case, by arranging the optical fibers 23 in an interleaved manner, a higher density of optical fibers 23 can be arranged in the X direction. As a result, even when the spacing between the optical input / output portions 5 of the connection target member 2 is further narrowed, each optical fiber 23 can be arranged with a high density corresponding to the spacing between the optical input / output portions 5. Therefore, without complicating the paths of the optical waveguides 15 in the arrangement transformation component 10, each optical fiber 23 of the optical connection component 20 can be connected to each optical input / output unit 5 of the connection target component 2 with high density. Thus, the optical connection assembly 1 according to this embodiment can achieve high density of the transmission path between the optical connection component 20 and the connection target component 2 while miniaturizing the optical connection assembly 1.

[0088] As in this embodiment, the offset d2 in the X direction between the central axis C of each fiber 23 included in the nth-level fiber array 25A and the central axis C of each fiber 23 included in the (n-1)th-level fiber array 25A is less than the outer diameter D25 of the fiber 23. In this case, the fibers 23 can be arranged at a higher density in the X direction, thus further increasing the density of the transmission path between the optical connection component 20 and the connection target component 2.

[0089] As in this embodiment, the spacing (stagger d1) in the X direction of each optical waveguide 15 arranged adjacent to each other in the Y direction may be the same as the spacing p11 in the X direction of each optical waveguide 15 in the first end face 11. In this case, each optical waveguide 15 of the arrangement transformation member 10 can be formed inside the arrangement transformation member 10 as a planar waveguide that varies in two dimensions (Y and Z directions). Therefore, compared with the case where three-dimensional optical waveguides 15 are formed inside the arrangement transformation member 10, the width of the arrangement transformation member 10 in the X direction can be further reduced while suppressing the complexity of the paths of each optical waveguide 15. As a result, the optical connection assembly 1 can be miniaturized more reliably.

[0090] As in this embodiment, the fiber array 25A can also be configured to be arranged side-by-side in the X direction. When the fiber array 25A includes more fibers 23, its length in the X direction varies depending on the number of fibers 23. Even in this case, according to the above configuration, it is not necessary to prepare new holding members of a length corresponding to the number of fibers 23; by combining existing multiple holding members 25, a fiber array 25A including two or more fibers 23 arranged in the X direction can be formed. Therefore, according to the above configuration, the optical connection assembly 1 can be manufactured at low cost using existing holding members 25.

[0091] As in this embodiment, the nth-level fiber array 25A in two or more fiber arrays 25A may be staggered in the X direction from the (n-1)th-level fiber array 25A adjacent to it in the Y direction. Alternatively, with the nth-level fiber array 25A held by the gripper 40 in a staggered manner from the (n-1)th-level fiber array 25A adjacent to it in the Y direction, the fiber 23 of the nth-level fiber array 25A may be positioned relative to the optical waveguide 15. In this staggered configuration of the fiber arrays 25A, by gripping the staggered portion (protruding portion P) of the holding member 25 of the fiber array 25A by the gripper 40, interference of the gripper 40 with the holding members 25 of different levels of fiber arrays 25A can be avoided, while easily positioning the fiber 23 of the fiber array 25A relative to the optical waveguide 15 of the arrangement conversion member 10.

[0092] As in this embodiment, the fiber alignment and connection processes can be performed repeatedly by gripping the fiber arrays 25A from the first to the Mth fiber array 25A in this order, and by gripping the protruding portion P of the mth fiber array 25A in the Y direction relative to the second end of the fiber array 25A adjacent to the mth fiber array 25A in the Y direction in the Y direction with the gripping member 40 in the Y direction. By repeatedly performing the alignment and connection processes from the first to the Mth fiber array 25A with the protruding portion P of the fiber array 25A gripped by the gripping member 40 in the Y direction, interference between the gripping member 40 and the holding members 25 of different levels can be more reliably avoided. This also makes it easier to position the optical fibers 23 of the fiber array 25A and the optical waveguide 15 of the alignment transformation member 10.

[0093] The optical connector and its manufacturing method disclosed herein are not limited to the embodiments described above. Modifications to the specific embodiments of the optical connector and its manufacturing method may also be made without departing from the spirit of the claims.

[0094] For example, in the optical connection assembly described above, the case where the fiber array includes two or more holding members has been explained. The fiber array may also include only one holding member for holding one or more fibers. In this case, during the manufacture of the optical connection assembly, in order to prevent the gripper holding the nth fiber array from interfering with fiber arrays of different levels, the alignment and connection processes may be performed while the holding member of the fiber array is gripped in the X direction (lateral direction).

[0095] In the above-described method for manufacturing an optical connector, the case where the fiber array at the first end of the optical connector is designated as the first, and the fiber array at the second end of the optical connector is designated as the Mth, and the fibers are connected to the alignment conversion unit in this order from the first to the Mth. The order in which the fibers are connected to the alignment conversion unit is not limited to this order. For example, it is also possible to designate the fiber array at the second end of the optical connector as the first, and the fiber array at the first end of the optical connector as the Mth, and perform the alignment and connection processes in this order from the first to the Mth.

Claims

1. An optical connection component, comprising: An arrangement transformation component includes a first end face, a second end face facing opposite to the first end face, and a plurality of optical waveguides extending from the first end face to the second end face. The plurality of optical waveguides are arranged in a first direction in the first end face, and an optical waveguide array is formed by two or more optical waveguides arranged in the first direction in the second end face. In the arrangement transformation component, the optical waveguide array is configured in N-order configurations in a second direction intersecting the first direction. N is an integer greater than or equal to 2; as well as An optical connection component has two or more fiber arrays, each of the two or more fiber arrays comprising: two or more optical fibers respectively connected to two or more optical waveguides; and a holding component arranging the two or more optical fibers in a first direction, wherein the two or more fiber arrays are configured in an N-order configuration in a second direction. The central axes of each of the two or more optical fibers included in the nth-level optical fiber array are offset from the central axes of each of the two or more optical fibers included in the corresponding (n-1)th-level optical fiber array in the first direction, wherein n is an integer greater than 2 and less than N.

2. The optical connection component according to claim 1, wherein, The offset in the first direction between the central axis of each of the two or more optical fibers included in the nth-level optical fiber array and the central axis of each of the two or more optical fibers included in the (n-1)th-level optical fiber array is less than the outer diameter of the optical fiber.

3. The optical connection assembly according to claim 1 or 2, wherein, The spacing of the plurality of optical waveguides arranged adjacent to each other in the second direction in the second end face in the first direction is the same as the spacing of the plurality of optical waveguides in the first end face in the first direction.

4. The optical connection assembly according to claim 1 or 2, wherein, Two or more of the fiber arrays are configured to be side by side in the first direction.

5. The optical connection component according to claim 4, wherein, The fiber array of the nth stage in one or more fiber arrays is offset from the fiber array of the (n-1)th stage that is adjacent to the fiber array of the nth stage in the second direction in the first direction.

6. A method for manufacturing an optical connection component, comprising: The preparation process includes preparing an arrangement transformation component and two or more fiber optic arrays. The arrangement transformation component includes a first end face, a second end face different from the first end face, and multiple optical waveguides extending from the first end face to the second end face. In the first end face, the multiple optical waveguides are arranged in a first direction. In the second end face, two or more optical waveguides arranged in the first direction form an optical waveguide array. In the arrangement transformation component, the optical waveguide array is configured in N-order configurations in a second direction intersecting the first direction. N is an integer greater than or equal to 2, and the two or more fiber arrays each include: two or more optical fibers; and a holding member to arrange the two or more optical fibers in the first direction; In the alignment process, at a position facing the second end face, while the nth-level fiber array is held by a gripper, two or more fibers included in the nth-level fiber array are positioned relative to two or more optical waveguides of the nth level, where n is an integer of 2 or more and less than N; and In the connection process, after positioning two or more optical fibers included in the nth-level fiber array relative to two or more optical waveguides of the nth-level, the fiber array is fixed to the second end face, thereby connecting two or more optical fibers included in the nth-level fiber array to the two or more optical waveguides of the nth-level. The core alignment process and the connection process are repeatedly performed in each of the levels up to level N, thereby configuring the fiber array in the second direction as level N with each of the central axes of the two or more fibers included in the fiber array of level n offset from each of the central axes of the two or more fibers included in the fiber array of the corresponding level n-1 in the first direction, thereby forming an optical connection component having the fiber array of level N.

7. The method for manufacturing an optical connector according to claim 6, wherein, In the preparation process, Two or more of the fiber optic arrays are to be configured to be side-by-side in the first direction. In the core-adjusting process, With the nth-level fiber array held by the gripper in a manner where the nth-level fiber array is adjacent to the nth-level fiber array in the second direction and the (n-1)th-level fiber array is staggered in the first direction, the two or more fibers included in the nth-level fiber array are positioned relative to the two or more optical waveguides.

8. The method for manufacturing an optical connector according to claim 7, wherein, When the fiber array at the first end of the optical connector in the first direction is designated as the first, the fiber array at the second end of the optical connector in the first direction is designated as the Mth, and the fiber array with the smallest offset from the (m-1)th fiber array to the second end in the first direction is designated as the mth, the fiber array is held by the gripper in this order from the first fiber array to the Mth fiber array, and the protruding portion of the mth fiber array that protrudes towards the second end in the first direction relative to the fiber array adjacent to the mth fiber array in the second direction is held by the gripper in the second direction, the alignment process and the connection process are repeatedly performed, where M is an integer greater than or equal to 2, and m is an integer greater than or equal to 2 and less than or equal to M.

Images