Optical Waveguide Inclined Surface Molding via Transfer Member
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Solution Overview
Problem
The manufacturing process of optical waveguide members is complicated due to difficulties in controlling the shape of the inclined surface, which affects the productivity and accuracy of the optical waveguide member formation.
Innovation Solution
A method involving a transfer member with a detachable metal film and sheet, where a first clad layer, core layer, and second clad layer are formed, and the inclined surface is created with an angle less than 90 degrees, allowing for easy detachment and patterning, and the inclusion of a reflective film for improved light transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If anisotropic etching is used to form the inclined surface of the core layer, then the inclined surface can be formed, but it is difficult to control the shape and the manufacturing process becomes complicated
Solution Approach 1:
The patent replaces the mechanical/chemical etching process with a molding process. The inclined surface is formed by pressing a mold against the core material layer, which is then cured to maintain the inclined shape. This substitution of the formation mechanism simplifies process control and eliminates the complexity of anisotropic etching.
Solution Approach 2:
The patent changes the state of the core material layer from liquid or paste to solid through curing. The inclined surface is formed while the material is in a pliable state, and then the material is cured to fix the shape. This parameter change (from liquid to solid) enables easy shape formation followed by stable structure maintenance.
2Shape
If the inclined surface is formed by anisotropic etching, then the core layer structure is created, but the manufacturing productivity is reduced due to process complexity
Solution Approach 1:
The molding process replaces the multi-step etching process, reducing the number of manufacturing steps. The inclined surface is formed in a single pressing operation followed by curing, which is faster and simpler than sequential etching steps, thereby improving manufacturing productivity.
Solution Approach 2:
The inclined surface shape is prepared in advance by molding the core material layer before final assembly. This preliminary formation of the inclined surface eliminates the need for subsequent etching steps, streamlining the manufacturing process and enhancing productivity.
3Productivity
If a transfer member with detachable metal film is used, then the manufacturing process is simplified and productivity is enhanced, but additional detachment and removal steps are required
Solution Approach 1:
The transfer member with detachable metal film acts as an intermediary carrier that simplifies the overall manufacturing process. Although it adds detachment and removal steps, it enables better control and standardization of the waveguide formation process, reducing complexity in other areas such as alignment and pattern transfer.
Data Source
AI summary
The present invention provides a method for manufacturing an optical waveguide. The inventive method includes steps of providing a transfer member comprising a transfer sheet and a first metal film. The transfer sheet and the first metal film are detachable from each other. A laminated body made of a core layer disposed between two clad layers is formed on the transfer member. The invention also relates to optical waveguides produced by the inventive process and devices incorporating the optical waveguides of the invention.