Self-Forming Optical Waveguide Curing via Core Light Leakage
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Solution Overview
Problem
The formation of self-forming optical waveguides using photocurable resin is hindered by cure shrinkage and incomplete curing, leading to deformation and deterioration of optical insertion loss due to UV irradiation and angle-dependent UV exposure.
Innovation Solution
A method involving the use of two multicore fibers with a photocurable resin that includes core and cladding part forming resins, where core parts are formed by selective polymerization and cladding parts are formed using light leakage from the core parts, preventing cure shrinkage and ensuring complete curing without UV irradiation from around the resin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the entire photocurable resin is irradiated with UV light to form multiple self-forming optical waveguides, then the cladding parts can be formed, but cure shrinkage occurs throughout the resin causing stress and deformation of core parts
Solution Approach 1:
The photocurable resin is divided into two distinct components: core part forming resin and cladding part forming resin. This segmentation allows selective curing - first the core parts are formed by light irradiation from cores, then the cladding parts are formed by light leakage from the cores. This prevents simultaneous curing of the entire resin, thereby eliminating cure shrinkage-induced stress and core deformation.
Solution Approach 2:
Different regions of the photocurable resin are given different properties through the use of resins with different refractive indices and light sensitivity characteristics. The core part forming resin has specific light sensitivity to be cured by direct irradiation, while the cladding part forming resin requires higher intensity light to be cured by light leakage. This local differentiation enables precise control over where and how curing occurs, preventing unwanted stress.
2Manufacturing precision
If UV irradiation is applied from around the photocurable resin, then curing can be achieved, but angle-dependent exposure causes incomplete curing of lower cores and deterioration of optical insertion loss
Solution Approach 1:
The core parts themselves serve as the light source for forming the cladding parts. After the cores are formed by light irradiation, the light propagating through these cores leaks out and automatically cures the surrounding cladding resin. This self-service mechanism ensures uniform curing of all cladding parts regardless of their position or angle, eliminating incomplete curing issues without requiring complex external irradiation systems.
Solution Approach 2:
Instead of using external light sources to cure the cladding resin from around the resin block, the invention inverts the approach by using the formed cores themselves as internal light sources. The light leakage from cores provides the necessary energy for cladding formation, reversing the traditional external-to-internal curing paradigm and achieving uniform curing throughout.
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 prevents stress and deformation in the core parts, reduces optical insertion loss, and stabilizes the optical and mechanical properties of the self-formed optical waveguides by controlling cure shrinkage and ensuring complete cladding formation.
Implementation Method 1
a core part forming resin that is polymerized when light in a predetermined wavelength band is incident from the cores
Implementation Method 2
a cladding part forming resin that is polymerized and cured when light of an intensity equal to or greater than that of the light incident on the core part forming resin is incident thereon
Data Source
AI summary
Manufacturing a self-forming optical waveguide from a photocurable resin and two multicore fibers each having n cores (n: a natural number≥2). The photocurable resin includes a core part forming resin polymerizable by incident light and has a refractive index na after curing, and a cladding part forming resin polymerizable and curable by incident light of an intensity≥the intensity of the light incident on the core part forming resin and has a refractive index nb after curing satisfying nb<na. The two multicore fibers face each other and the photocurable resin is positioned between them. Light incident on the photocurable resin originating from the cores of the two multicore fibers forms the core parts. Next, light incident on the core parts generates light leakage into the cladding part forming resin and polymerizes and cures the cladding part forming resin around the core parts.