Optical Waveguide Mirror Face Formation via Photocurable Resin Pressing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing optical waveguides with mirror faces suffer from issues such as optical loss due to cutting debris, cumbersome processes, shadowing of reflective films, and increased coupling loss, particularly when using dicing blades or stamper-based techniques.
Innovation Solution
A method involving the lamination of a photocurable resin sheet on a substrate, followed by forming mirror faces using a die with 45-degree inclined blades, and subsequent selective exposure and development to create a smooth mirror surface, eliminating the need for cutting operations and reducing light loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a dicing blade is used to cut the optical waveguide to form mirror faces, then the mirror face can be formed after waveguide fabrication, but cutting debris remains around the optical waveguide causing optical loss
Solution Approach 1:
The mirror face is formed during the waveguide fabrication process itself rather than as a subsequent cutting operation. The inclined plane is created while the optical waveguide material is still in its formable state, eliminating the need for post-fabrication cutting and avoiding the generation of cutting debris that would cause optical loss.
2Manufacturing precision
If a stamper with raised pattern is pressed into liquid photocurable resin to form mirror faces, then mirror shapes can be formed on the stamper, but liquid resin sticks to the stamper surface requiring cleaning after each pressing operation
Solution Approach 1:
The invention changes the physical state parameter of the resin from liquid to sheet form. By using a photocurable resin sheet instead of liquid resin, the resin maintains its shape during pressing and does not stick to the stamper surface, eliminating the need for cleaning operations while still allowing precise mirror face formation through the pressing process.
3Manufacturing precision
If a core groove with mirror shape is created and filled with resin, then mirror faces can be formed, but shadowing of the mirror face occurs making it difficult to form a reflective film
Solution Approach 1:
The mirror face is formed as an integral part of the waveguide structure during fabrication, creating a smooth, exposed surface. This preliminary formation of the mirror face with proper geometry and surface quality enables subsequent reflective film deposition without shadowing issues, as the mirror face is not confined within a groove that would block film deposition equipment.
4Manufacturing precision
If the core is formed by filling a core groove with resin and curing the resin, then the core structure is created, but shrinkage during curing subjects the mirror face to shear strain causing peeling of the reflective film
Solution Approach 1:
The invention changes the fabrication approach by forming the mirror face during the waveguide structure creation process itself, rather than as a separate post-processing step. This integrated approach ensures that the mirror face and core structure are formed simultaneously without relative movement or shrinkage, eliminating shear strain that would cause reflective film peeling while still achieving proper core structure formation.
5Ease of operation
If a stamper pattern is provided with a taper to lower release resistance, then the stamper can be released from the resin, but only trapezoidal core cross-sectional shapes can be created increasing coupling loss
Solution Approach 1:
The invention changes the resin form from liquid to sheet, which fundamentally alters the forming mechanism. The photocurable resin sheet can be pressed to create various cross-sectional shapes including rectangular, square, or other geometries without requiring stamper tapers for release. This eliminates the constraint to trapezoidal shapes while maintaining easy stamper release, as the sheet resin does not stick to the stamper surface during pressing.
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 approach results in optical waveguides with reduced light loss and improved reflection efficiency, as the smooth mirror faces formed directly transfer the die's surface state without cutting debris, and the process simplifies core and mirror alignment, enhancing the optical performance of optoelectronic composite wiring boards.
Implementation Method 1
a core forming step of forming a core having the mirror face positioned at an end thereof by selectively exposing to light, and developing, the photocurable resin sheet
Data Source
AI summary
In order to provide a method of manufacturing an optical waveguide, which enables the formation of a smooth mirror face, the following method of manufacturing an optical waveguide having a mirror face is used. The method includes: a photocurable resin sheet laminating step of laminating an uncured photocurable resin sheet for forming a core on a surface of a first cladding layer that has been formed on a substrate; a mirror face forming step of forming a mirror face for guiding light to the core by pressing a die provided with a blade having, in a cross-section, a 45° inclined plane into the photocurable resin sheet; a core forming step of forming a core having the mirror face positioned at an end thereof by selectively exposing to light, and developing, the photocurable resin sheet; and a cladding layer forming step of forming a second cladding layer so as to bury the core.