Optical Waveguide Light Path Conversion Mirror Assembly
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Solution Overview
Problem
The existing methods for manufacturing optical waveguides are inefficient and costly due to the need for complex equipment and processes, particularly in forming light path converting portions, which slows down production and increases costs.
Innovation Solution
A method involving the use of a light path conversion component with a protruding portion having a light path conversion inclined surface covered with a metal layer, which serves as a mirror, is integrated into the optical waveguide structure, allowing for simplified manufacturing by pre-forming the component and mounting it onto the waveguide, eliminating the need for expensive vapor deposition equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the metal layer is formed on the groove portion by mask vapor deposition after the groove portion is formed, then the light path conversion mirror is obtained, but the manufacturing time increases and manufacturing efficiency deteriorates
Solution Approach 1:
The light path conversion component with the metal layer pre-formed on the inclined surface is prepared in advance as a separate component. This preliminary formation of the metal layer on the groove portion allows the component to be manufactured separately with high precision, then assembled into the optical waveguide, thereby improving overall manufacturing efficiency while maintaining mirror formation precision.
2Manufacturing precision
If the metal layer is formed on the groove portion by mask vapor deposition, then the light path conversion mirror is obtained, but the equipment cost increases
Solution Approach 1:
The manufacturing process is segmented into two independent stages: first, the light path conversion component with pre-formed metal layer is manufactured separately; second, this component is assembled into the optical waveguide. This segmentation allows the metal layer to be formed using simpler, more cost-effective equipment rather than requiring complex mask vapor deposition equipment, thereby reducing overall device complexity and cost.
3Manufacturing precision
If the groove portion with inclined surface is formed by processing the optical waveguide, then the light path conversion structure is obtained, but the manufacturing time increases
Solution Approach 1:
The light path conversion component including the inclined surface and metal layer is prepared in advance as a separate pre-formed component. This preliminary preparation eliminates the need for time-consuming post-processing steps to create the inclined surface and metal layer structure during the main optical waveguide manufacturing process, thereby significantly reducing total manufacturing time while maintaining structural precision.
Solution Approach 2:
The manufacturing process is divided into separate modules: the light path conversion component is manufactured independently with its inclined surface and metal layer pre-formed, then assembled into the optical waveguide. This segmentation allows parallel processing of components, eliminating sequential processing delays and reducing overall manufacturing time while preserving the precision of the light path conversion structure.
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 simplifies the formation of light path converting portions, reduces production time and costs, and improves the smoothness and reflectivity of the light path conversion mirror, enhancing the optical waveguide's performance and manufacturing efficiency.
Implementation Method 1
a light path of a light that propagates through the core layer is converted toward a first cladding layer side by the light path conversion mirror
Data Source
AI summary
A method of manufacturing an optical waveguide, includes preparing a light path conversion component including a structure in which a protruding portion having a light path conversion inclined surface is covered with a metal layer and the metal layer serves as a light path conversion mirror, and a structural body in which a core layer is formed on a first cladding layer and an opening portion is provided in an end side of a light path of the core layer, arranging the light path conversion mirror of the light path conversion component in the opening portion of the core layer, and forming a second cladding layer covering the core layer, wherein a light path of a light that propagates through the core layer is converted toward a first cladding layer side by the light path conversion mirror.