Optical Fiber Array NIL Process for Smooth, Precise V-Grooves
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Solution Overview
Problem
Current methods for producing optical fiber arrays face limitations such as the inability to apply UV light for adhesive curing from the bottom side of V-grooves, thermal expansion coefficient mismatch, and surface roughness issues, which affect the precision and performance of the final products.
Innovation Solution
The use of nanoimprint lithography (NIL) process to create an optical fiber array with high precision patterns and smooth surfaces, utilizing optical-grade materials suitable for mass production and high transmission performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional machining with V-shaped diamond wheel is used to create V-grooves, then the grooves can be formed, but surface roughness limits the usage and precision of the technique
Solution Approach 1:
The patent replaces conventional mechanical machining with V-shaped diamond wheels with a nanoimprint lithography process. This involves forming a negative V-groove pattern in a resist layer, then using adhesive deposition and UV curing to create precise V-grooves with smooth surfaces, eliminating the surface roughness issues inherent in mechanical machining methods.
Solution Approach 2:
The patent changes the manufacturing parameters by using a multi-step adhesive curing process with UV light applied from the bottom side of the substrate. This allows precise control of adhesive polymerization and V-groove formation, achieving smooth surfaces and high precision that cannot be obtained through conventional mechanical machining parameters.
2Manufacturing precision
If conventional precision plastic molding is used to create V-grooves, then the grooves can be formed, but shrinkage during molding and surface structure accuracy determine the final product quality
Solution Approach 1:
The patent replaces conventional precision plastic molding with a nanoimprint lithography process that uses resist layer patterning, adhesive deposition, and UV curing. This eliminates the shrinkage issues inherent in molding processes and provides superior surface structure accuracy for the V-grooves and fiber array.
Solution Approach 2:
The patent changes the manufacturing approach by using a bottom-side UV curing method through the substrate, allowing precise control of the adhesive polymerization process. This eliminates the shrinkage and accuracy limitations of conventional molding while maintaining processability.
3Ease of manufacture
If UV light for adhesive curing is applied from the bottom side of the V-groove, then curing can be achieved, but conventional methods do not allow this approach
Solution Approach 1:
The patent inverts the conventional adhesive curing approach by applying UV light from the bottom side of the substrate rather than from the top. This allows uniform curing of the adhesive in the V-grooves while maintaining access to all grooves, solving the problem of curing uniformity that plagues conventional top-side illumination methods.
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
Enables high precision pattern transfer and smooth surfaces, achieving optical-grade performance suitable for mass production and overcoming the limitations of conventional methods.
Implementation Method 1
The UV light for adhesive curing cannot be applied from the bottom side of the V-groove
Data Source
AI summary
An optical fiber array includes a groove plate having a plurality of grooves disposed on a top surface thereof; and an optical component plate having a plurality of first optical components disposed on a first surface of the optical component plate and a plurality of second optical components disposed on a second surface of the optical component plate, the second surface being opposite the first surface.