Mirror-Reflecting Film Transfer on Optical Waveguide Inclined Faces
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Solution Overview
Problem
Conventional methods for forming mirror-reflecting films on optical waveguides in optical wiring boards require expensive vacuum processing equipment and result in excessive metal usage and adhesion difficulties due to the inability to precisely target metal deposition.
Innovation Solution
A method using a multilayer film with a base, metal layer, and adhesive layer, where the adhesive layer intervenes between the base and the inclined face, allowing for precise transfer and bonding of the metal layer onto the waveguide, reducing material costs and simplifying the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vacuum evaporation or sputtering methods are used to form mirror-reflecting films, then the films can be formed on inclined faces, but expensive vacuum processing equipment is required
Solution Approach 1:
The patent introduces an adhesive layer as an intermediary between the base and the inclined face. This adhesive layer enables the mirror-reflecting film to be formed on the inclined face through bonding rather than vacuum deposition, eliminating the need for expensive vacuum processing equipment while maintaining film formation reliability
Solution Approach 2:
The patent replaces the vacuum-based physical deposition system with a mechanical bonding system using adhesive layers. This substitution eliminates complex vacuum equipment while achieving the same functional result of forming mirror-reflecting films on inclined surfaces
2Reliability
If vacuum deposition methods are used, then films can be formed on inclined faces, but excessive metal is used and adhesion is difficult
Solution Approach 1:
The patent applies adhesive material locally at the bonding interface between the base and the inclined face, rather than using excessive metal material throughout. This localized application of adhesive ensures proper adhesion while minimizing material waste and reducing the total amount of metal required
Solution Approach 2:
The adhesive layer serves as a mediator that facilitates bonding between the base and the mirror-reflecting film on the inclined face. This intermediary layer solves the adhesion difficulty by providing a bonding interface specifically designed for attachment, eliminating the need for excessive metal material
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables the cost-effective and precise formation of mirror-reflecting films using minimal metal, improving the economic and technical feasibility of optical wiring board manufacturing while maintaining high reflectivity and reducing optical scattering losses.
Implementation Method 1
a multilayer film, in which a base, a metal layer and an adhesive layer are layered in this order, is used, and in which the metal layer is transferred and bonded to an inclined face for mirror-reflecting film formation provided on a waveguide with the adhesive layer of the multilayer film intervening
Data Source
AI summary
An aspect of the present invention is directed to a method for forming a mirror-reflecting film on a waveguide in an optical wiring board, characterized in that a multilayer film, in which a base, a metal layer and an adhesive layer are layered in this order, is used, and the metal layer is transferred and bonded to an inclined face for mirror-reflecting film formation provided on the waveguide, with the adhesive layer of the multilayer film intervening. The present invention provides a method which, when forming a mirror-reflecting film on a waveguide in an optical wiring board, enables inexpensive and easy formation of the mirror-reflecting film, using the smallest quantity of metal possible and employing comparatively simple facilities and techniques.