Optical Waveguide Laminate Laser Machining

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Solution Overview

Problem

Opto-electric hybrid boards with protruding edge portions are prone to damage during handling and assembly, leading to quality deterioration and poor workability due to susceptibility to impacts and misalignment issues, and existing laser machining techniques struggle to efficiently remove unnecessary portions without damaging the optical waveguide.

Innovation Solution

An optical waveguide laminate with an organic base material layer, where the laser light transmittance of the optical waveguide and the organic base material layer differ significantly, allowing for precise removal of the organic base material layer by laser machining without impairing the optical waveguide, with the organic base material layer being laminated to at least one surface of the optical waveguide and satisfying specific transmittance inequalities.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the electric circuit board E protrudes outwardly from the optical waveguide W, then the manufacturing process is simplified, but the protruding portions are susceptible to impacts and become broken or cracked off during handling and transport

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidimpact resistance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent inverts the conventional configuration by making the optical waveguide protrude outwardly from the electric circuit board instead of the board protruding from the waveguide. This inversion resolves the contradiction by providing impact resistance through the protruding optical waveguide structure while maintaining manufacturing simplicity through the standard process of forming the board first and then creating the waveguide on its surface.

Inventive Principle:

Principle #13The other way round (Inversion)

2Reliability

If the opening of the recess 11a is designed to leave large clearance from the outside shape of the electric circuit board E, then damages to protruding portions are prevented, but precise positioning of the cores 7 in the recess 11a is not achieved

Engineering Contradiction:

Improvedamage preventionVSAvoidpositioning precision

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent inverts the positioning approach by having the optical waveguide protrude from the board and fit into the ferrule recess, rather than having the board fit into the ferrule. This allows the recess opening to be designed with precise dimensions matching the optical waveguide core, achieving both damage prevention and precise positioning simultaneously.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent uses the outline shape of the optical waveguide as a precise template or copy for designing the ferrule recess dimensions. By making the recess match the optical waveguide's outline shape, precise positioning is achieved without requiring large clearances, thus resolving the contradiction between damage prevention and positioning precision.

Inventive Principle:

Principle #26Copying

3Productivity

If laser light transmittance Q of the organic base material layer is low for efficient removal, then the organic layer can be removed efficiently, but thermal damage may occur to the optical waveguide underneath

Engineering Contradiction:

Improvemachining efficiencyVSAvoidthermal damage

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent applies parameter changes by selecting a laser wavelength (355 nm ultraviolet) where the organic base material layer has low transmittance for efficient removal, while the optical waveguide material (glass or quartz) maintains high transmittance to avoid thermal damage. This wavelength-specific parameter change resolves the contradiction between machining efficiency and thermal damage prevention.

Inventive Principle:

Principle #35Parameter changes

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

The solution enables efficient removal of the organic base material layer with high machining accuracy and quality, preventing thermal damage to the optical waveguide and maintaining high-quality opto-electric hybrid boards with improved impact resistance and precise positioning capabilities.

Implementation Method 1

a portion of the organic base material layer is lacking because a portion of the organic base material layer has been removed by a laser beam

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentUS10914893B2Optical waveguide laminate and method of manufacturing same

Publication Date: 2021.02.09 NITTO DENKO CORP

AI summary

There is provided an optical waveguide laminate in which an organic base material layer comprised of an insulation layer and a coverlay is laminated to one surface of an optical waveguide and in which a portion of the organic base material layer is lacking so that the optical waveguide is uncovered. Inequalities P≥70% and P−Q≥25% are satisfied where P is the laser light transmittance in at least a portion of the optical waveguide, the laser light having a predetermined wavelength range, and Q is the laser light transmittance of at least a portion of the organic base material layer. In this optical waveguide laminate, the organic base material layer laminated to the optical waveguide is elaborately removed without being impaired or thermally damaged by laser machining.