Manufacturing method of optical module device and manufacturing method of cutting jig

Abstract

To provide a manufacturing method of optical module device capable of manufacturing an optical module device having desired optical properties, and a manufacturing method of cutting jig.SOLUTION: The manufacturing method includes a first step of creating a relation expression of: a first distance X between a first position P1 serving as reference when a connector 3 is positioned at a cutting jig 4 and a second position P2 where the optical fiber 2 is cut; and a second distance Y between a third position P3 where an optical focal point is positioned and a fourth position P4 where one end face 21 of the optical fiber 2 is positioned. A second step includes selecting the cutting jig 4 with the first desired distance X based on the relation expression and cutting the optical fiber 2. A third step includes attaching the connector 3 to an optical module 5 and manufacturing the optical module device 1 with the second distance Y. The first step includes fourth to seventh steps. The fourth step includes trial-manufacturing the plurality of cutting jigs 4 each having the plurality of first distances X. The fifth step includes using the plurality of cutting jigs 4 to cut the plurality of optical fibers 2.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The present invention relates to a method for manufacturing an optical module device and a method for manufacturing a cutting jig. [Background technology]

[0002] 2. Description of the Related Art A manufacturing method for an optical module device is known in which a connector for fixing an optical fiber is attached to an optical module (see, for example, Patent Document 1 below).

[0003] In the method for manufacturing an optical module device described in Patent Document 1, first, a connector for fixing an optical fiber is attached to a cutting jig. The connector includes a ferrule. The ferrule is movable relative to the optical fiber. Next, the optical fiber is cut by the cutting jig. When cutting the optical fiber, an end portion exposed from the ferrule is removed.

[0004] Next, the connector is removed from the cutting jig, and then the connector is attached to the optical module, thereby completing the manufacture of an optical module device including the optical module, the optical fiber, and the connector.

[0005] In the manufacture of an optical module device, the focal position of the optical module is set to the cut surface of the optical fiber or its vicinity. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] JP 2014-89223 A Summary of the Invention [Problem to be solved by the invention]

[0007] The position of the cut surface of the optical fiber needs to be adjusted according to the optical properties required in the optical module device.

[0008] However, in the method described in Patent Document 1, the end of the optical fiber exposed from the ferrule is cut in a uniform manner. Therefore, when a connector for fixing such an optical fiber is attached to an optical module, the cut surface of the optical fiber is uniformly positioned relative to the optical focal point of the optical module. This causes a problem that an optical module device having desired optical properties cannot be manufactured.

[0009] The present invention provides a method for manufacturing an optical module device, which can manufacture an optical module device having desired optical properties, and a method for manufacturing a cutting jig used in the manufacturing method of an optical module device. [Means for solving the problem]

[0010] The present invention (1) is a manufacturing method for an optical module device, comprising the steps of: attaching a connector for fixing an optical fiber to a cutting jig; cutting the optical fiber with the cutting jig; removing the connector from the cutting jig; and then attaching the connector to an optical module, the method comprising the steps of: creating a relational expression between a first distance between a first position, which is a reference when the connector is positioned in the cutting jig, and a second position where the optical fiber is cut, in the cutting jig; and a second distance between a third position, where an optical focus is located, and a fourth position where an end face of the optical fiber is located, in the optical module device; and creating a relational expression between the first distance and the second distance, which is a first distance and a fourth distance, in the optical module device, between a third position where an optical focus is located and a fourth position where an end face of the optical fiber is located, in the cutting jig. The method includes a second step of selecting a cutting tool and cutting the optical fiber using the cutting tool, and a third step of attaching the connector to the optical module to manufacture the optical module device having the desired second distance, wherein the first step includes a fourth step of prototyping a plurality of the cutting tools each having a plurality of different first distances, a fifth step of cutting each of the plurality of the optical fibers using each of the plurality of cutting tools, a sixth step of attaching each of the plurality of connectors to the optical module and measuring the plurality of second distances, and a seventh step of creating the relational equation between the plurality of first distances and the plurality of second distances.

[0011] In a method for manufacturing an optical module device, in a first step, a relational expression is created between a first distance related to a cutting jig and a connector and a second distance related to an optical module device and an end face of an optical fiber. In a second step, a cutting jig having a desired first distance is selected based on the relational expression, and the optical fiber is cut using the cutting jig. In a third step, the connector is attached to the optical module to manufacture the optical module device. Therefore, an optical module device can be manufactured in which the second distance between a third position that is an optical focus in the optical module and a fourth position on the end face of the optical fiber is a desired value. As a result, an optical module device having desired optical properties can be manufactured.

[0012] In a fourth step, a plurality of cutting tools each having a plurality of different first distances are prototyped, in a fifth step, a plurality of optical fibers are cut using each of the above-mentioned plurality of cutting tools, and in a sixth step, a plurality of connectors are attached to an optical module and a plurality of second distances are measured, so that in a seventh step, a relational equation can be created in which the first distances and the second distances match well.

[0013] Therefore, by selecting in advance a cutting tool having a first distance corresponding to the desired second distance, an optical fiber can be cut using the cutting tool and a connector for fixing the optical fiber can be attached to an optical module, thereby reliably manufacturing an optical module device having the desired optical properties.

[0014] The present invention (2) includes a method for manufacturing an optical module device as described in (1), wherein the cutting jig includes a blade, a plate that faces the blade when the blade moves, and a positioning part that positions the connector on the plate, and in the fourth step, the position of the positioning part is set to the first position and the position of the surface of the plate is set to the second position, and in the fifth step, the positioning part positions the connector relative to the plate, and the blade slides on the surface of the plate.

[0015] In this manufacturing method, the first position and the second position can be easily set, and the first distance can be easily set based on them.

[0016] The present invention (3) includes a method for manufacturing an optical module device described in (1) or (2), in which the optical module includes an optical lens, and in the sixth step, the focal position of the optical lens is set to the third position.

[0017] In this manufacturing method, the third position, which is the focal position of the optical lens, can be easily identified.

[0018] The present invention (4) includes a method for manufacturing an optical module device described in (3), in which the connector has a ferrule that is inserted into the optical fiber and is movable relative to the optical fiber, and in the sixth step, the position of the end face of the ferrule or a position near it is set as the focal position of the optical lens.

[0019] In the sixth step of the method for manufacturing the optical module device, the position of the end face of the ferrule is set to be the focal position of the optical lens or a position in the vicinity thereof, so that the focal position of the optical lens can be easily set.

[0020] The present invention (5) includes a method for manufacturing an optical module device described in any one of (2) to (4), wherein the connector further includes a positioned portion, the optical module further includes a second positioning portion, and in the fifth step, the positioning portion positions the positioned portion, and in the sixth step, the second positioning portion positions the positioned portion.

[0021] In the manufacturing method for the optical module device, the positioning part performs positioning with respect to the common positioned part in the fifth step, and the second positioning part performs positioning in the sixth step. Therefore, the connector can be easily positioned by the common positioned part in each of the fifth step and the sixth step.

[0022] The present invention (6) includes the method for manufacturing an optical module device described in (5), in which the positioned portion is a protrusion, the positioning portion and the second positioning portion are each a hole, and in the fifth step, the positioned portion fits into the positioning portion, and in the sixth step, the positioned portion fits into the second positioning portion.

[0023] In this manufacturing method, in the fifth step, the positioned portion which is a protrusion fits into the positioning portion which is a hole, and in the sixth step, the positioned portion which is a protrusion fits into the second positioning portion which is a hole, so that the connector can be easily positioned on both the cutting jig and the optical module.

[0024] The present invention (7) includes a method for manufacturing a cutting jig used in the method for manufacturing an optical module device described in any one of (1) to (6), comprising: a first step of creating a relational equation between a first distance between a first position, which is a reference when the connector is positioned in the cutting jig, and a second position at which the optical fiber is cut, and a second distance between a third position at which an optical focus is located, and a fourth position at which an end face of the optical fiber is located, in the optical module device; and a second step of manufacturing the cutting jig having a desired first distance based on the relational equation, wherein the first step includes a fourth step of prototyping a plurality of the cutting jigs each having a plurality of first distances different from each other; a fifth step of cutting each of the plurality of the optical fibers using each of the plurality of the cutting jigs; a sixth step of attaching each of the plurality of the connectors to the optical module and measuring a plurality of the second distances; and a seventh step of creating the relational equation between the plurality of the first distances and the plurality of the second distances. Effect of the Invention

[0025] The method for manufacturing an optical module device of the present invention, which uses a cutting jig manufactured by the method for manufacturing a cutting jig of the present invention, can manufacture an optical module device having desired optical properties. [Brief description of the drawings]

[0026] [Figure 1] Fig. 1A is a cross-sectional view of a cutting jig used in a manufacturing method according to an embodiment of the present invention, and Fig. 1B is a cross-sectional view taken along line ZZ in Fig. 1A. [Diagram 2] Fig. 2A is a cross-sectional view of a connector attached to the cutting jig shown in Fig. 1A, and Fig. 2B is a cross-sectional view taken along line ZZ in Fig. 2A. [Diagram 3] 11A to 11C are cross-sectional views of a process of cutting the connector using a cutting jig. [Figure 4] 11 is a cross-sectional view of the connector removed from the cutting jig. FIG. [Diagram 5] Fig. 5A is a cross-sectional view of the optical module, and Fig. 5B is a cross-sectional view taken along line ZZ in Fig. 5A. [Figure 6] FIG. 2 is a cross-sectional view of an optical module. [Figure 7] FIG. 2 is a cross-sectional view of an embodiment in which the second distance is 0. [Figure 8] FIG. 13 is a cross-sectional view of an embodiment in which the second distance is a negative number. [Figure 9] 13 is a relational expression between the first distance and the second distance. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0027] 1. One embodiment An embodiment of a method for manufacturing an optical module device and a method for manufacturing a cutting jig according to the present invention will be described with reference to FIGS. 1A to 9. FIG.

[0028] The manufacturing method of the optical module device 1 (see Figure 6) includes attaching a connector 3 (see Figures 2A and 2B) that secures an optical fiber 2 to a cutting jig 4 (see Figures 1A and 1B), cutting the optical fiber 2 with the cutting jig 4 (see Figure 3), removing the connector 3 from the cutting jig 4 (see Figure 4), and then attaching the connector 3 to an optical module 5 (see Figures 5A and 5B).

[0029] 1.1 Optical fiber 2 The optical fiber 2 shown in FIG. 2A has flexibility. As shown in FIG. 2B, the optical fiber 2 has a substantially circular cross section. The optical fiber 2 includes a core (not shown) and a clad (not shown) in this order toward the outside in the radial direction. The radial direction is included in the orthogonal direction perpendicular to the direction in which the optical fiber 2 extends. Hereinafter, the direction in which the optical fiber 2 extends is defined as a first direction. The optical fiber 2 may further include an overclad. The overclad contacts the outer peripheral surface of the core in the radial direction. Examples of the material of the optical fiber 2 include resin and ceramics. Examples of the resin include acrylic resin and epoxy resin. Examples of the ceramic include glass. A preferable material of the optical fiber 2 is resin from the viewpoint of flexibility. If the material of the optical fiber 2 is resin, the optical fiber 2 is called a plastic optical fiber (POF). The diameter of the optical fiber 2 is, for example, 10 μm or more and, for example, 10000 μm or less.

[0030] 1.2 Connector 3 2A, the connector 3 fixes one end of the optical fiber 2. The connector 3 includes a connector casing 31, a fixing member 32, a positioned member 33, and a ferrule .

[0031] 1.2.1 Connector casing 31 As shown in Fig. 2B, the connector casing 31 is disposed at an outer portion of the connector 3 in a cross-sectional view. The connector casing 31 houses the fixing member 32 and a part of the ferrule 34. As shown in Fig. 2A, the connector casing 31 extends in a first direction. The connector casing 31 has a cylindrical shape (specifically, a rectangular cylindrical shape).

[0032] 1.2.2 Fixing member 32 The fixing member 32 is disposed at the other end of the connector 3 in the first direction. Specifically, the fixing member 32 is disposed at the other end inside the connector casing 31 in the first direction. The fixing member 32 extends in the first direction. As shown in FIGS. 2A and 2B, the fixing member 32 has a tubular shape (specifically, a rectangular tubular shape). The outer surface of the fixing member 32 contacts the inner surface of the connector casing 31. The fixing member 32 is immovable relative to the connector casing 31.

[0033] The fixing member 32 is penetrated by the optical fiber 2. The inner circumferential surface of the fixing member 32 contacts the outer circumferential surface of the optical fiber 2. The fixing member 32 supports the optical fiber 2 so that it cannot move in the first direction. In this way, the fixing member 32 fixes the optical fiber 2.

[0034] 1.2.3 Positioned member 33 As shown in FIG. 2A, the positioned member 33 is disposed in the middle of the connector 3 in the first direction. The positioned member 33 is disposed on one side relative to the fixed member 32 in the first direction. The positioned member 33 is attached to one end (outer peripheral surface) of the connector casing 31 in the second direction. The second direction is a direction perpendicular to the first direction, and corresponds to the up-down direction on the paper in FIGS. 2A and 2B. The positioned member 33 has a plate shape extending in the first direction and the second direction. The positioned member 33 protrudes from one end (outer peripheral surface) of the connector casing in the second direction to one side in the second direction. The positioned member 33 includes a positioned portion 331.

[0035] 1.2.3.1 Positioned portion 331 2B, the positioned portion 331 is disposed on one surface of the positioned member 33 in the third direction. The third direction is perpendicular to the first direction and the second direction. In this embodiment, the positioned portion 331 is a protrusion. The positioned portion 331 protrudes from one surface of the positioned member 33 toward one side in the third direction.

[0036] 1.2.4 Ferrule 34 As shown in FIG. 2A, the ferrule 34 is disposed on one side of the connector 3 in the first direction. A part of the ferrule 34 is exposed from the connector casing 31, and the remaining part of the ferrule 34 is housed in the connector casing 31. The remaining part of the ferrule 34 is disposed in the internal space of the middle part and one end part of the connector casing 31 in the first direction. The ferrule 34 is disposed on one side of the fixing member 32 in the first direction with a gap therebetween. The ferrule 34 has a cylindrical shape (specifically, a rectangular cylindrical shape). The axis of the ferrule 34 is aligned along the first direction. The ferrule 34 is movable (slidable) relative to the connector casing 31 in the first direction.

[0037] The ferrule 34 is inserted into the optical fiber 2. The ferrule 34 exposes one end of the optical fiber 2 in the first direction. The inner peripheral surface of the ferrule 34 is spaced apart from or in contact with the outer peripheral surface of the optical fiber 2 by a small gap. The ferrule 34 supports the optical fiber 2 so as to be movable in the first direction. The ferrule 34 is slidable in the first direction relative to the optical fiber 2 and the connector casing 31.

[0038] 1.3 Cutting jig 4 As shown in Fig. 3, the cutting jig 4 cuts the optical fiber 2 fixed to the connector 3. As shown in Figs. 1A and 1B, the cutting jig 4 includes a cutting casing 41, a guide 42, and a blade 43.

[0039] 1.3.1 Cutting casing 41 The cutting casing 41 allows the optical fiber 2 (see FIG. 3) to pass therethrough, and allows the connector 3 (see FIG. 3) to be attached thereto. The cutting casing 41 includes a first casing 411, a second casing 412, and a positioning portion 413.

[0040] 1.3.1.1 First casing 411 The first casing 411 extends in a first direction. The first casing 411 has a cylindrical shape. The connector casing 31 is inserted into the first casing 411, and the connector casing 31 can be attached thereto.

[0041] 1.3.1.2 Second casing 412 The second casing 412 is disposed at one end of the first casing 411 in the second direction. The second casing 412 extends from one end of the first casing 411 in the second direction toward one side in the second direction. The second casing 412 has a pair of plates 412A, 412B, a connecting plate 412C, and a groove 4121.

[0042] Each of the pair of plates 412A, 412B extends from one end of the first casing 411 in the second direction toward one side in the second direction. The pair of plates 412A, 412B are spaced apart from each other in the third direction. Each of the pair of plates 412A, 412B extends in the first direction.

[0043] The connecting plate 412C connects one end of the plate 421 in the second direction to one end of the second plate 422 in the second direction.

[0044] The groove 4121 is partitioned by a pair of plates 412A, 412B and a connecting plate 412C. The groove 4121 communicates with the internal space of the first casing 411.

[0045] 1.3.1.3 Positioning portion 413 The positioning portion 413 is included in the plate 412A, which is disposed on one side in the third direction, of the pair of plates 412A, 412B. The positioning portion 413 is disposed in the middle of the plate 412A in the first direction. In this embodiment, the positioning portion 413 is a hole. The positioning portion 413 penetrates the plate 412A in the thickness direction.

[0046] 1.3.2 Guide 42 The guide 42 is disposed at one end of the cutting jig 4 in the first direction. The guide 42 is disposed adjacent to one side of the cutting casing 41 in the first direction. The guide 42 includes a plate 421, a second plate 422, and a connecting portion 423.

[0047] The plate 421 is continuous with one end of the cutting casing 41 in the first direction. The plate 421 extends in the second direction and the third direction. The plate 421 has a through hole 4211.

[0048] The through hole 4211 penetrates the plate 421 in the first direction. The through hole 4211 communicates with the internal space of the first casing 411. The inner dimension of the through hole 4211 is the same as or larger than the diameter of the optical fiber 2 (see FIG. 3).

[0049] The second plate 422 is disposed on one side of the plate 421 in the first direction to face the plate 421 with a gap therebetween. The second plate 422 has the same shape as the plate 421. The second plate 422 has a second through hole 4221.

[0050] The second through hole 4221 penetrates the second plate 422 in the first direction. The second through hole 4221 overlaps with the through hole 4211 when projected in the first direction.

[0051] The connecting portion 423 connects the other end of the plate 421 in the second direction to the other end of the second plate 422 in the second direction.

[0052] 1.3.3 Blade 43 The blade 43 is movable relative to the guide 42 in the second direction. The movement of the blade 43 is guided by the guide 42. The blade 43 includes a cutting edge 431. The cutting edge 431 is disposed between the plate 421 and the second plate 422. The movement trajectory of the cutting edge 431 can pass between the through hole 4211 and the second through hole 4221. When the blade 43 moves, the blade 43 faces at least the plate 421. In this embodiment, when the blade 43 moves, the blade 43 faces the plate 421 and the second plate 422.

[0053] 1.4 Optical Modules5 6, the optical module 5 is disposed in an outer portion of the optical module device 1. The optical module 5 is equipped with a connector 3 and optically connected to an optical fiber 2. As shown in FIGS. 5A and 5B, the optical module 5 includes a module casing 51, an optical lens 52, and a light receiving / emitting element 53.

[0054] 1.4.1 Module casing 51

[0055] 5A, the module casing 51 is disposed at an outer portion of the optical module 5. The module casing 51 houses an optical lens 52 and a light receiving / emitting element 53. The module casing 51 includes a third casing 511, a fourth casing 512, a second positioning portion 513, a cover 514, and a partition plate 515. The module casing 51 also includes a lens-element housing portion 516 and a fiber housing portion 517.

[0056] 1.4.1.1 Third casing 511 The third casing 511 is disposed over the entire module casing 51 in the first direction. The third casing 511 extends in the first direction. The third casing 511 has a cylindrical shape (specifically, a rectangular cylindrical shape). The third casing 511 houses a partition plate 515, an optical lens 52, and a light receiving / emitting element 53.

[0057] 1.4.1.2 Fourth casing 512 5A and 5B, the fourth casing 512 is disposed at one end (outer peripheral surface) of the third casing 511 in the second direction. As shown in FIG. 5A, in detail, the fourth casing 512 is attached to the other end and the middle part of the third casing 511 in the first direction. The fourth casing 512 extends from one end of the third casing 511 in the second direction toward one side in the second direction. The fourth casing 512 has a pair of second plates 512A, 512B, a second connecting portion 512C, and a second groove 5121.

[0058] Each of the pair of second plates 512A, 512B extends from one end of the third casing 511 in the second direction toward one side in the second direction. The pair of second plates 512A, 512B are spaced apart from each other in the third direction. Each of the pair of second plates 512A, 512B extends in the first direction.

[0059] The second connecting portion 512C connects one end of the second plate 512A in the second direction to one end of the second plate 512B in the second direction.

[0060] The second groove 5121 is partitioned by a pair of second plates 512A, 512B. The second groove 5121 communicates with the internal space of the third casing 511.

[0061] 1.4.1.3 Second positioning portion 513 The second positioning portion 513 is included in the second plate 512A, which is disposed on one side in the third direction of the pair of second plates 512A, 512B. The second positioning portion 513 is disposed in the middle of the second plate 512A in the first direction. As shown in FIG. 5B, in this embodiment, the second positioning portion 513 is a hole. The second positioning portion 513 penetrates the second plate 512A in the thickness direction.

[0062] 1.4.2 Lid 514 The lid 514 is disposed at one end of the module casing 51 in the first direction. Specifically, the lid 514 connects one end edge of the third casing 511 in the first direction. As a result, the lid 514 closes one end of the third casing 511 in the first direction. The lid 514 extends in the second direction and the third direction. The lid 514 has a plate shape.

[0063] 1.4.3 Partition plate 515 The partition plate 515 is disposed in a middle portion inside the module casing 51 in the first direction. The partition plate 515 divides (partitions) the internal space of the third casing 511 into two portions (a lens-element accommodating portion 516 and a fiber accommodating portion 517 described below) in the first direction. The partition plate 515 extends in the second and third directions. The partition plate 515 has a third through hole 5151.

[0064] The third through hole 5151 penetrates the partition plate 515 in the first direction. The third through hole 5151 is disposed in the center of the partition plate 515 in each of the second and third directions. When projected in the first direction, an optical focus (reference symbol P3, described later) of the optical module 5 is disposed within the third through hole 5151.

[0065] 1.4.4 Lens-element housing 516 The lens-element housing portion 516 is one end of the optical module 5 in the first direction. The lens-element housing portion 516 includes one end of the third casing 511 in the first direction, the lid 514, the optical lens 52, and the light emitting / receiving element 53.

[0066] 1.4.5 Fiber Receptacle 517 The fiber accommodating portion 517 is the other end and intermediate portion of the optical module 5 in the first direction. The fiber accommodating portion 517 is disposed adjacent to the other side of the lens-element accommodating portion 516 in the first direction. The fiber accommodating portion 517 includes the other end and intermediate portion of the third casing 511 in the first direction, a fourth casing 512, a second positioning portion 513, and a partition plate 515. The inner shape (inner form) and inner dimensions of the fiber accommodating portion 517 are the same as those of the cutting jig 4.

[0067] 1.4.6 Optical Lenses52 The optical lens 52 is included in the lens-element housing portion 516. The optical lens 52 is disposed on one surface of the partition plate 515 in the first direction. The optical lens 52 is configured to collect light emitted from a light receiving / emitting element 53 described below and irradiate it on one end surface 21 (see FIG. 6 ) of the optical fiber 2 and / or to collect light emitted from the one end surface 21 of the optical fiber 2 and irradiate it on the light receiving / emitting element 53.

[0068] 1.4.7 Light-emitting / receiving element 53 The light emitting / receiving element 53 is included in the lens-element housing portion 516. The light emitting / receiving element 53 is disposed facing one side of the optical lens 52 in the first direction with a gap therebetween. The light emitting / receiving element 53 is disposed on the other surface of the lid 514 in the first direction. The light emitting / receiving element may be a photodiode and / or a vertical cavity surface emitting laser diode (VCSEL).

[0069] 1.5 Overview of steps 1 to 3 The method for manufacturing the optical module device 1 includes a first step, a second step, and a third step.

[0070] 1.5.1 First step As shown in FIG. 9, in the first step, a relational expression relating to a first distance X and a second distance Y is created.

[0071] 1.5.2 First distance X 1A and 3, the first distance X relates to the cutting jig 4 and the connector 3. Specifically, the first distance X is the length between the first position P1 and the second position P2.

[0072] The first position P1 is a reference position when the connector 3 is positioned in the cutting jig 4. On the other hand, the second position P2 is a position where the optical fiber 2 is cut in the cutting jig 4 to which the connector 3 is attached.

[0073] Specifically, the first distance X is the length from the positioning portion 413 of the cutting jig 4 to the plate 421 in the first direction. More specifically, the first distance X is the length from one edge of the positioning portion 413 to one surface of the plate 421 in the first direction. Therefore, the first position P1 is the position of one edge of the positioning portion 413 in the first direction. The second position P2 is the position of one surface of the plate 421 in the first direction.

[0074] 1.5.3 Second distance Y The second distance Y will be described in detail later in the sixth step. As shown in Fig. 9, in the first step, a relational expression between the first distance X and the second distance Y is created.

[0075] 1.5.4 Details of the first step The first step includes a fourth step, a fifth step, a sixth step, and a seventh step. In the first step, the fourth step, the fifth step, the sixth step, and the seventh step are carried out in this order.

[0076] 1.5.5 4th step In the fourth step, as shown in Figs. 1A and 1B, a plurality of cutting jigs 4 each having a plurality of different first distances X are fabricated. Note that Figs. 1A and 1B depict only one cutting jig 4, and do not depict a plurality of cutting jigs 4. The above-mentioned first distances X are different between the plurality of cutting jigs 4. Meanwhile, the inner shapes (inner shapes) and inner dimensions of the cutting casing 41 (including the positioning portion 413) in cross sections along the second and third directions (see Fig. 1B) are the same between the plurality of cutting jigs 4.

[0077] In the fourth step, as described above, the position of the positioning portion 413 is set as the first position P1. Also, in the fourth step, the position of one surface (an example of a front surface) of the plate 421 in the first direction is set as the second position P2. In the fourth step, a plurality of first positions P1 are set that are located at positions relatively different from the second position P2 in the first direction. The first distance X is determined from the first position P1 and the second position P2 described above.

[0078] 1.5.6 5th step In the fifth step, as shown in Fig. 3, each of the multiple optical fibers 2 is cut using each of the multiple cutting jigs 4. Note that Fig. 3 also depicts only one cutting jig 4, and does not depict multiple cutting jigs 4. Figs. 2A and 2B also depict only one connector 3 and one optical fiber 2, and do not depict multiple connectors 3 and multiple optical fibers 2.

[0079] In a fifth step, each of the multiple connectors 3 is inserted into each of the multiple cutting casings 41.

[0080] The multiple connectors 3 have the same shape and dimensions. The positioned portions 331 of the multiple connectors 3 are also arranged in the same manner.

[0081] 1.5.6.1 Cleavage of an Optical Fiber 2 Using a Cleavage Tool 4 3, first, a method of cutting one optical fiber 2 using one cutting jig 4 will be described. One connector 3 is inserted into one cutting casing 41. At that time, the connector 3 is moved relative to the cutting jig 4 from the other side to one side in the first direction.

[0082] Specifically, the connector casing 31 is inserted into the first casing 411. At the same time, the positioned member 33 (see FIG. 2B) is inserted into the groove 4121 (see FIG. 1B). Then, as shown in FIG. 3, the positioned portion 331 (protrusion) fits into the positioning portion 413 (hole). At this time, one end face of the ferrule 34 in the first direction moves toward the other side relative to one end of the connector casing 31 and the optical fiber 2. Thus, one end face of the connector casing 31 in the first direction comes into contact with the plate 421. Also, one end faces of the connector casing 31 and the ferrule 34 in the first direction become flush with each other in the second direction.

[0083] In the fifth step, the positioning portion 413 positions the positioned portion 331. The positioning portion 413 positions the connector 3 with respect to the plate 421. The connector 3 is positioned with respect to the cutting jig 4 by the positioning portion 413.

[0084] As a result, the connector casing 31 is immovable relative to the cutting casing 41 in the first direction, that is, the connector casing 31 is fixed to the cutting casing 41.

[0085] Moreover, one end of the optical fiber 2 passes through the through hole 4211 and the second through hole 4221 in that order. One end edge (imaginary line) of the optical fiber 2 is disposed on one side of the guide 42 in the first direction.

[0086] In the fifth step, to subsequently cut the optical fiber 2 using the cutting jig 4, the blade 43 is moved relative to the optical fiber 2 so that the blade tip 431 passes between the through hole 4211 and the second through hole 4221. Also, the blade 43 slides on one surface (front surface) of the plate 421 in the first direction.

[0087] This cuts off one end of the optical fiber 2. As a result, one end face 21 is newly formed on the optical fiber 2 fixed to the connector 3. The one end face 21 is a cut surface. The one end face 21 of the optical fiber 2 is located at approximately the same position as one surface of the plate 421 in the first direction.

[0088] As shown in FIG. 4, one connector 3 is removed from one cutting jig 4 (see FIG. 3).

[0089] In the connector 3 removed from the cutting jig 4, one end face of the ferrule 34 in the first direction advances to one side in the first direction and is disposed on one side of the connector casing 31 in the first direction. When projected in the second direction, one end face 21 of the optical fiber 2 overlaps (is encompassed by) the ferrule 34.

[0090] 1.5.6.2 Cleavage of another optical fiber 2 using another cleaving tool 4

[0091] 3, another optical fiber 2 is cut using another cutting tool 4. The cutting of the other optical fiber 2 using the other cutting tool 4 is similar to the above. In this way, each of the multiple (two or more) cutting tools 4 is used to cut each of the multiple (two or more) optical fibers 2. In this way, each of the multiple (two or more) one end faces 21 is formed on each of the multiple (two or more) connectors 3.

[0092] In this fifth step, the plurality of optical fibers 2 having the plurality of first distances X different from one another are fixed to the plurality of connectors 3, respectively.

[0093] Thereafter, the other connector 3 is removed from the other cutting jig 4 as shown in FIG.

[0094] 1.5.7 6th step As shown in Fig. 6, in the sixth step, each of the multiple connectors 3 is attached to one optical module 5, and multiple second distances Y are measured. Specifically, one connector 3 is attached to the optical module 5, and the second distance Y is measured, and then another connector 3 is attached to the one optical module 5, and the second distance Y is measured. The second distance Y corresponding to one connector 3 is different from the second distance Y corresponding to the other connector 3. The above measurement of the second distance Y is repeated for the number of connectors 3.

[0095] In short, in the sixth step, a plurality of second distances L are obtained using a plurality of connectors 3 and one optical module 5.

[0096] 1.5.7.1 Attaching the First Connector 3 to the Optical Module 5 and Measuring the Second Distance Y First, the attachment of the first connector 3 to the optical module 5 and the measurement of the second distance Y will be described in detail. In the sixth step, the first connector 3 is attached to the optical module 5 first.

[0097] Specifically, as shown in FIG. 6, one connector casing 31 is inserted into the third casing 511 of the fiber accommodating portion 517 .

[0098] Specifically, the connector casing 31 (see FIG. 4) is inserted into the fiber accommodating portion 517 (see FIG. 5B). At the same time, the positioned member 33 (see FIG. 4) is inserted into the second groove 5121 (see FIG. 5B). Furthermore, the connector 3 is moved from the other side to the one side in the first direction relative to the optical module 5. Then, in a sixth step, the positioned portion 331 (protrusion) fits into the second positioning portion 513 (hole), as shown in FIG. 6.

[0099] As a result, the second positioning portion 513 positions the positioned portion 331. The connector 3 is positioned with respect to the optical module 5 by the second positioning portion 513. The connector casing 31 is immovable relative to the module casing 51 in the first direction, that is, the connector casing 31 is fixed to the module casing 51.

[0100] One end face of the connector casing 31 in the first direction contacts the partition plate 515. One end face of the ferrule 34 in the first direction contacts the partition plate 515 while moving to the other side relative to one end of the connector casing 31 and the optical fiber 2. In this embodiment, the respective one end faces of the connector casing 31 and the ferrule 34 in the first direction are flush with each other in the second direction.

[0101] In contrast, one end of the optical fiber 2 is exposed from the ferrule 34. In this embodiment, one end edge of the optical fiber 2 is disposed within (facing) the third through-hole 5151.

[0102] 1.5.7.2 Second distance Y Next, the second distance Y is measured. The second distance Y relates to the optical module device 1 and one end face 21 of the optical fiber 2. Specifically, the second distance Y is the length between the third position P3 and the fourth position P4. The third position P3 is an optical focal position in the optical module device 1. Meanwhile, the fourth position P4 is the position of one end face 21 of the optical fiber 2.

[0103] In the sixth step, the focal position (light collecting position) of the optical lens 52 is the third position P3. In the sixth step, the position of the end face of the ferrule 34 in the first direction is set as the focal position of the optical lens 52. On the other hand, in the sixth step, the position of one end face 21 of the optical fiber 2 is set as the fourth position P4.

[0104] Specifically, the second distance Y is the distance from the optical focal position in the optical module device 1 to one end face 21 of the optical fiber 2 in a direction toward one side of the first direction.

[0105] In this embodiment, since the fourth position P4 is disposed on one side in the first direction with respect to the third position P3, the second distance Y is a positive number.

[0106] On the other hand, as shown in FIG. 7, when the third position P3 and the fourth position P4 are disposed at the same position in the first direction, the second distance Y is zero.

[0107] On the other hand, as shown in FIG. 8, when the fourth position P4 is disposed on the other side in the first direction with respect to the third position P3, the second distance Y is a negative number.

[0108] In a sixth step, a plurality of second distances Y are measured corresponding to the plurality of optical module devices 1. The second distances Y are measured by, for example, a measuring microscope.

[0109] 1.5.8 7th step As shown in Fig. 9, in the seventh step, a relational expression between a plurality of first distances X and a plurality of second distances Y is created. Points (circles) are plotted on a graph with the first distances X on the horizontal axis and the second distances Y on the vertical axis. In this embodiment, the relational expression is obtained from the plurality of plots. In this embodiment, the relational expression is expressed by a linear function, and is preferably expressed as Y = aX + b.

[0110] 1.6 Second process In the second step, a cutting jig 4 having a desired first distance X is selected based on the relational expression, and the cutting jig 4 is used to cut the optical fiber.

[0111] In the second step, a desired second distance Y is specified depending on the application and physical properties of the optical module device 1, and a cutting jig 4 having a first distance X corresponding to the second distance Y is selected.

[0112] The cutting jig 4 provided for the trial manufacture in the fourth step is regarded as a product if it has the first distance X corresponding to the desired second distance Y in the relational expression. Alternatively, a final product having a specific first distance X can be manufactured separately. The cutting jig 4 is manufactured by carrying out the first step and the second step. In other words, the manufacturing process of the cutting jig 4 includes the first step and the second step. The manufacturing process of the cutting jig 4 does not include the third step described below.

[0113] 1.7 Third step In the third step, the connector 3 is attached to the optical module 5 to manufacture the optical module device 1 having the desired second distance Y. The attachment of the connector 3 to the optical module 5 in the third step is similar to that in the sixth step. The optical module device 1 manufactured in the third step is provided as a product.

[0114] 2. Effects In the manufacturing method of the optical module device 1, in the first step, a relational expression is created between the first distance X related to the cutting jig 4 and the connector 3 and the second distance Y related to the optical module device 1 and one end face 21 of the optical fiber 2. In the second step, a cutting jig 4 having a desired first distance X is selected based on the relational expression, and the optical fiber 2 is cut using the cutting jig 4. In the third step, the connector 3 is attached to the optical module 5 to manufacture the optical module device 1. Therefore, it is possible to manufacture the optical module device 1 in which the second distance Y between the third position P3, which is the optical focus of the optical module 5, and the fourth position P3 of the one end face 21 of the optical fiber 2 is set to a desired value according to its application and purpose. As a result, it is possible to manufacture the optical module device 1 having the desired optical properties. Examples of the optical properties include the optical connection strength and the amount of return light.

[0115] For example, when high optical connection strength is required, an optical module device 1 is manufactured having the second distance Y corresponding to the region α surrounded by the dashed dotted line in Fig. 9. The region α is a region where the second distance Y is 0 and its vicinity (see Fig. 7).

[0116] On the other hand, when a small amount of return light is required, an optical module device 1 having a second distance Y corresponding to region β and / or region γ is manufactured. Region β is a positive region where the second distance Y is away from 0 (see FIG. 6). Region γ is a negative region where the second distance Y is away from 0 (see FIG. 8).

[0117] In a fourth step, a plurality of cutting jigs 4 each having a plurality of different first distances X are fabricated. In a fifth step, a plurality of optical fibers 2 are cut using each of the plurality of cutting jigs 4. In a sixth step, a plurality of connectors 3 are attached to an optical module 5, and a plurality of second distances Y are measured. In a seventh step, a relational expression that satisfactorily matches the first distance X and the second distance Y can be created.

[0118] Therefore, by selecting in advance a cutting jig 4 having a first distance X corresponding to a desired second distance Y, the optical fiber 2 can be cut using the cutting jig 4, and the connector 3 for fixing the optical fiber 2 can be attached to an optical module, thereby reliably manufacturing an optical module device 1 having the desired optical properties.

[0119] In the method for manufacturing the optical module device 1, the first position P1 and the second position P2 can be easily set, and the first distance X can be easily set based on them.

[0120] Moreover, in the manufacturing method of the optical module device 1, the third position P3, which is the focal position of the optical lens, can be easily identified.

[0121] Furthermore, in the sixth step of the method for manufacturing the optical module device 1, the position of one end face of the ferrule 34 in the first direction or a position nearby the position is set as the focal position of the optical lens 52, so that the focal position of the optical lens 52 can be easily set.

[0122] In the manufacturing method of the optical module device 1, the positioning portion 413 performs positioning with respect to the common positioned portion 331 in the fifth step, and the second positioning portion 513 performs positioning in the sixth step. Therefore, the connector 3 can be easily positioned by the common positioned portion 331 in both the fifth step and the sixth step.

[0123] In the manufacturing method of the optical module device 1 described above, in the fifth step, the positioned portion 331 which is a protrusion fits into the positioning portion 413 which is a hole, as shown in Fig. 3, and in the sixth step, the positioned portion 331 which is a protrusion fits into the second positioning portion 513 which is a hole, as shown in Fig. 6. This makes it possible to easily position the connector 3 relative to the cutting jig 4 and the optical module 5.

[0124] <Modification of one embodiment> In the following modifications, the same components and steps as those in the above-described embodiment are denoted by the same reference numerals, and detailed description thereof will be omitted. In addition, each modification can achieve the same effects as those in the above-described embodiment, unless otherwise specified. Furthermore, the embodiment and the modifications can be appropriately combined.

[0125] In a modified example, the positioned portion 331 is a hole. The positioning portion 413 and the second positioning portion 513 are each a protrusion. The positioning portion 413 and the second positioning portion 513 fit into the common positioned portion 331. [Explanation of symbols]

[0126] 1. Optical module device 2. Optical Fiber 3 Connector 4 Cutting tool 5 Optical Module 21 One end face 34 Ferrule 43 Blades 52 Optical Lenses 331 Positioned part 413 Positioning part 421 board 513 Second positioning part 412A Plate X First distance Y Second distance P1 First position P2 Second position P3 Third position P4 Fourth position

Claims

1. a manufacturing method for an optical module device, comprising the steps of: attaching a connector for fixing an optical fiber to a cutting tool; cutting the optical fiber with the cutting tool; removing the connector from the cutting tool; and then attaching the connector to an optical module, a first step of creating a relational expression between a first distance between a first position, which is a reference when the connector is positioned in the cutting tool, and a second position, where the optical fiber is cut, in the cutting tool, and a second distance between a third position, where an optical focus is located, and a fourth position, where an end face of the optical fiber is located, in the optical module device; a second step of selecting the cutting tool having the desired first distance based on the relational expression, and cutting the optical fiber using the cutting tool; and a third step of attaching the connector to the optical module to produce the optical module device having the desired second distance. The first step comprises: a fourth step of prototyping a plurality of the cutting jigs each having a plurality of first distances different from one another; a fifth step of cutting each of the plurality of optical fibers using each of the plurality of cutting jigs; a sixth step of attaching each of the plurality of connectors to the optical module and measuring a plurality of the second distances; and a seventh step of creating the relational expression between the plurality of first distances and the plurality of second distances.

2. The cutting tool is Blade and a plate that faces the blade as the blade moves; a positioning portion for positioning the connector on the plate, In the fourth step, a position of the positioning portion is set to the first position, and a position of the surface of the plate is set to the second position, The method for manufacturing an optical module device according to claim 1 , wherein in the fifth step, the positioning portion positions the connector relative to the plate, and the blade slides on a surface of the plate.

3. The optical module includes an optical lens; 3. The method for manufacturing an optical module device according to claim 1, wherein in the sixth step, a focal position of the optical lens is set to the third position.

4. the connector includes a ferrule that is inserted into the optical fiber and is movable relative to the optical fiber; The method for manufacturing an optical module device according to claim 3 , wherein in the sixth step, the position of the end face of the ferrule or a position in the vicinity thereof is set as a focal position of the optical lens.

5. The connector further includes a positioned portion, The optical module further includes a second positioning portion, In the fifth step, the positioning portion positions the positioned portion, 5. The method for manufacturing an optical module device according to claim 2, wherein in the sixth step, the second positioning portion positions the positioned portion.

6. the positioned portion is a protrusion, each of the positioning portion and the second positioning portion is a hole, In the fifth step, the positioned portion is fitted into the positioning portion, The method for manufacturing an optical module device according to claim 5 , wherein in the sixth step, the positioned portion is fitted into the second positioning portion.

7. A method for manufacturing a cutting jig used in the method for manufacturing an optical module device according to any one of claims 1 to 6, comprising the steps of: a first step of creating a relational expression between a first distance between a first position, which is a reference when the connector is positioned in the cutting tool, and a second position where the optical fiber is cut, and a second distance between a third position, which is an optical focus position, and a fourth position, which is an end face of the optical fiber, in the optical module device; and a second step of manufacturing the cutting jig having the desired first distance based on the relational expression, The first step comprises: a fourth step of prototyping a plurality of the cutting jigs each having a plurality of first distances different from one another; a fifth step of cutting each of the plurality of optical fibers using each of the plurality of cutting jigs; a sixth step of attaching each of the plurality of connectors to the optical module and measuring a plurality of the second distances; and a seventh step of creating the relational equation between the plurality of first distances and the plurality of second distances.

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