This application claims priority under 35USC119 from Japanese Patent Applications No. 2005-336283 and No. 2005-336284, the disclosures of which are incorporated by reference herein.
1. Technical Field
The present invention relates to a method of manufacturing an optical waveguide for guiding light to be utilized for a mobile device or the like as waveguide light, and an optical waveguide manufactured by this method.
2. Related Art
There are methods, in which resins are laminated and resin layers are processed, for manufacturing an optical waveguide.
According to these methods, high-performance optical waveguides can be manufactured easily.
According to this manufacturing method, however, the polymer resin to be the cladding layer is applied to the substrate, and the polymer resin to be the core layer is applied to the cladding layer so that a double-layered resin layer is formed.
For this reason, the substrate which does not function as the optical waveguide is necessary at the manufacturing steps, and thus the manufactured waveguide is an expensive product.
In the case where a power supply to a mobile device or the like is necessary, an electric conductive line is necessary independently from the optical waveguide.
The present invention has been made in view of the above circumstances and provides an optical waveguide and an optical waveguide manufacturing method.
According to an aspect of the present invention, an optical waveguide manufacturing method is provided. The optical wave guide manufacturing method includes: (a) preparing a polymer film, applying polymer resin with refractive index different from the polymer film to the polymer film and curing the resin, so as to manufacture a double-layered polymer film having a cladding layer and a core layer with refractive index higher than the cladding layer; (b) cutting the core layer using a dicing saw with a blade for enabling cutting of the resin layer so as to process the core layer into core portions of an optical waveguide; and (c) filling concave portions of the cut core layer with polymer resin with the same refractive index as the cladding layer, covering the core portions with the polymer resin, and curing the polymer resin so as to form a cladding resin layer.
Embodiments of the present invention will be described in detail based on the following figures, wherein:
A manufacturing method for an optical waveguide according to a first embodiment of the present invention is explained below following the order of the steps with reference to
As shown in
For example, a material, in which the refractive index of the core layer 14 is 1.51 and a difference in the refractive index between the core layer 14 and the cladding layer is 0.01 to 0.2, is selected. Various films such as an alicyclic olefin film, an acrylic film, an epoxy film and a polyimide film can be used, but since particularly the layer with high refractive index becomes core portions 14A of an optical waveguide, the light transmittance should be high. Since a layer with low refractive index serves as the cladding layer, even the layer with inferior light transmittance to the layer with high refractive index can be utilized.
It is preferable that the thickness of the double-layered polymer film 18 falls within a range of 70 μm to 200 μm in order to heighten following-up property of the optical waveguide with respect to deformation. Further, due to the similar reason, it is preferable that the width of the double-layered polymer film 18 falls within a range of 0.5 mm to 10 mm, and more preferably a range of 1 mm to 5 mm.
At the next step, as shown in
As shown in
When the core layer 14 is cut by the multi-blade 20, it is divided by the blades 22 with large outer diameter, and the surfaces of the divided core layers are cut by the blades 24 with small outer diameter. In such a manner, a plurality of core portions 14A of the optical waveguide are processed.
For example, in order to form the plural core portions 14A with width of 50 μm and pitch of 250 μm, the blades 22 with large outer diameter with thickness of 50 μm and the blades 24 with small outer diameter with thickness of 200 μm are combined alternately. As a result, the core portions 14A can be processed.
At the next step, as shown in
At the next step, as shown in
The double-layered polymer film 18 is, therefore, formed without using a substrate, and the optical waveguide can be manufactured by the inexpensive double-layered polymer film 18.
In the manufacturing method according to the first exemplary embodiment, the polymer film 12 to be the cladding layer is fixed to the fixing table, and the polymer resin to be the core layer 14 with higher refractive index than the polymer film 12 is applied to the polymer film 12 and is cured, so that the double-layered polymer film is manufactured. Instead of this method, the polymer film is fixed to be the core layer 14 to the fixing table, and polymer resin to be a cladding layer with lower refractive index is applied to the core layer and is cured and the double-layered polymer film may be manufactured. In this case, when the double-layered polymer film is manufactured, the core layer is provided on the lower side. For this reason, the double-layered film is turned upside down so that the core layer is arranged on the upper side, and it should be cut by the dicing saw. In this case, for example, an alicyclic olefin film whose refractive index is 1.51 may be used as the core layer, and a fluorinated acrylic resin with low refractive index may be used as the cladding layer.
An optical waveguide manufacturing method according to a second exemplary embodiment of the present invention is explained below following the steps with reference to
As shown in
At the next step, as shown in
At the next step, as shown in
At the next step, as shown in
In the manufacturing method according to the second exemplary embodiment, the first polymer film 42 to be the first cladding layer and the second polymer film 46 to be the second cladding layer are fixed to the fixing table 40 and the fixing table 44, respectively. Further, the UV curing polymer resin with higher refractive index than the first polymer film 42 is uniformly applied to the first polymer film 42. The second polymer film 46 is overlapped with the first polymer film 42 and is irradiated with an UV ray so as to be cured. As a result, the core layer 48 is formed, and the triple-layered polymer film 52 is manufactured. Instead of this, however, the UV curing polymer resin to be the cladding layer with lower refractive index than the core layer is uniformly applied to both the surfaces of the polymer film to be the core layer and is irradiated with an UV ray so as to be cured. In such a manner, the triple-layered polymer film may be manufactured.
An optical waveguide manufacturing method according to a third exemplary embodiment of the present invention is explained below following the steps with reference to
As shown in
For example, a material in which the refractive index of the core layer 114 is 1.51 and a difference in the refractive index between the core layer 114 and the cladding layer is 0.01 to 0.2, is selected. Various films such as an alicyclic olefin film, an acrylic film, an epoxy film and a polyimide film can be used, but since particularly the layer with high refractive index becomes core portions 114A of the optical waveguide, the light transmittance should be high. Since a layer with low refractive index serves as the cladding layer, even the layer with lower light transmittance than the layer with high refractive index can be utilized.
It is preferable that the thickness of the double-layered polymer film 118 falls within a range of 70 μm to 200 μm in order to heighten following-up property of the optical waveguide with respect to deformation. Further, due to the similar reason, it is preferable that the width of the double-layered polymer film 118 falls within a range of 0.5 mm to 10 mm, and more preferably a range of 1 mm to 5 mm.
At the next step, as shown in
As shown in
When the core layer 114 is cut by the multi-blade 120, the core layer 114 is divided by the blades 122 with large outer diameter, and the surfaces of the divided core layer 114 is cut by the blades 124 with small outer diameter. As a result, a plurality of core portions 114A of the optical waveguide are processed. Further, simultaneously with the processing of the core portions 114A, the core layer 114 is cut by the blades 122 with large outer diameter, and disposing portions 130 for disposing electric conductive lines for power supply are processed at both ends of the core layer 114, respectively, so as to sandwich the core portions 114A.
For example, in order to form the plural core portions 114A with width of 50 μm and pitch of 250 μm, the blades 122 with large outer diameter with thickness of 50 μm and the blades 124 with small outer diameter with thickness of 200 μm are combined alternately. As a result, the core portions 114A can be processed.
At the next step, as shown in
At the next step, as shown in
At the next step, as shown in
The double-layered polymer film 118 is, therefore, formed without using a substrate, and the inexpensive optical waveguide having the electric conductive lines 132 for power supply can be manufactured by the inexpensive double-layered polymer film 118.
In the manufacturing method according to the third exemplary embodiment, the polymer film 112 to be the cladding layer is fixed to the fixing table, and the polymer resin to be the core layer 114 with higher refractive index than the polymer film 112 is applied to the polymer film 112 and is cured, so that the double-layered polymer film is manufactured. Instead of this method, however, the polymer film to be the core layer is fixed to the fixing table, and polymer resin to be a cladding layer with lower refractive index than the core layer is applied to the core layer and is cured. In such a manner, the double-layered polymer film may be manufactured. In this case, when the double-layered polymer film is manufactured, the core layer is provided on the lower side. For this reason, the double-layered film is turned upside down so that the core layer is arranged on the upper side, and it should be cut by the dicing saw. In this case, for example, an alicyclic olefin film whose refractive index is 1.51 may be used as the core layer, and a fluorinated acrylic resin with low refractive index may be used as the cladding layer.
An optical waveguide manufacturing method according to a fourth exemplary embodiment of the present invention is explained below following the steps with reference to
As shown in
For example, a material, in which the refractive index of the core layer 64 is 1.51 and a difference in the refractive index between the core layer 64 and the cladding layer is 0.01 to 0.2, is selected. Various films such as an alicyclic olefin film, an acrylic film, an epoxy film and a polyimide film can be used, but since particularly the layer with high refractive index becomes a core portion 64A of an optical waveguide, the light transmittance should be high. Since a layer with low refractive index serves as the cladding layer, even the layer with light transmittance inferior to the layer with high refractive index can be utilized.
It is preferable that the thickness of the double-layered polymer film 68 falls within a range of 70 μm to 200 μm in order to heighten following-up property of the optical waveguide with respect to deformation. Further, due to the similar reason, it is preferable that the width of the double-layered polymer film 68 falls within a range of 0.5 mm to 10 mm, and more preferably a range of 1 mm to 5 mm.
At the next step, as shown in
The multi-blade 70 is composed of two kinds of blades with different outer diameters, blades 74 with small outer diameter are provided between blades 72 with large outer diameter, respectively.
When the core layer 64 is cut by the multi-blade 70, it is divided by the blades 72 with large outer diameter, and the surfaces of the divided core layer 64 are cut by the blades 74 with small outer diameter. In such a manner, a plurality of core portions 64A of the optical waveguide are processed.
For example, in order to form the plural core portions 64A with width of 50 μm and pitch of 250 μm, the blades 72 having large outer diameter and thickness of 50 μm, and the blades 74 having small outer diameter and thickness of 200 μm are combined alternately. As a result, the core portions 64A can be processed.
At the next step, as shown in
At the next step, as shown in
At the next step, as shown in
The double-layered polymer film 68 is, therefore, formed without using a substrate, and the inexpensive optical waveguide having the electric conductive lines 76A for power supply can be manufactured by the inexpensive double-layered polymer film 68 and the polymer film 76 with electric conductive lines.
In the manufacturing method according to the fourth exemplary embodiment, the polymer film 62 to be the cladding layer is fixed to the fixing table, and the polymer resin to be the core layer 64 with higher refractive index than the polymer film 62 is applied to the polymer film 62 and is cured, so that the double-layered polymer film 68 is manufactured. Instead of this method, however, the polymer film to be the core layer 14 is fixed to the fixing table, and polymer resin to be a cladding layer with lower refractive index is applied to the core layer and is cured. In such a manner, the double-layered polymer film may be manufactured. In this case, when the double-layered polymer film is manufactured, the core layer is provided to the lower side. For this reason, the double-layered film is turned upside down so that the core layer is arranged on the upper side, and it should be cut by the dicing saw. In this case, for example, an alicyclic olefin film whose refractive index is 1.51 may be used as the core layer, and a fluorinated acrylic resin with low refractive index may be used as the cladding layer.
An optical waveguide manufacturing method according to a fifth exemplary embodiment of the invention is explained below following the steps with reference to
As shown in
At the next step, as shown in
The multi-blade 154 is composed of two kinds of blades with different outer diameters, and blades 156 with small outer diameter are provided between blades 155 with large outer diameter, respectively.
When the core layer 148 is cut by the multi-blade 154, it is divided by the blades 155 with large outer diameter, and the core portions 148A of the plurality of optical waveguide are processed. Further, simultaneously with the processing of the core portions 148A, the core layer 148 is cut by the blades 155 with large outer diameter, and disposing portions 157 for disposing electric conductive lines for power supply are processed at both ends of the core layer 148, respectively, so as to sandwich the core portions 148A.
At the next step, as shown in
At the next step, as shown in
At the next step, as shown in
The triple-layered polymer film 152 is, therefore, formed without using a substrate, and the inexpensive optical waveguide having the electric conductive line 158 for power supply can be manufactured by the inexpensive triple-layered polymer film 152.
In the manufacturing method according to the fifth exemplary embodiment, the first polymer film 142 to be the first cladding layer and the second polymer film 146 to be the second cladding layer are fixed to the fixing table 140 and the fixing table 144, respectively. Further, the UV curing polymer resin with higher refractive index than the first polymer film 142 is uniformly applied to the first polymer film 142. The second polymer film 146 is overlapped with the first polymer film 142 and is irradiated with an UV ray so as to be cured. As a result, the core layer 148 is formed, and the triple-layered polymer film 152 is manufactured. Instead of this, however, the UV curing polymer resin to be the cladding layer with lower refractive index than the core layer is uniformly applied to both the surfaces of the polymer film to be the core layer and is irradiated with an UV ray so as to be cured. In such a manner, the triple-layered polymer film may be manufactured.
An optical waveguide manufacturing method according to a sixth exemplary embodiment of the present invention is explained below following the steps with reference to
As shown in
At the next step, as shown in
The multi-blade 94 is composed of two kinds of blades with different outer diameters, and blades 96 with small outer diameter are provided between blades 95 with large outer diameter, respectively.
The core layer 88 is cut by the multi-blade 94 and is divided by the blades 95 with large outer diameter, so that a plurality of core portions 88A of the optical waveguide are processed.
At the next step, as shown in
At the next step, as shown in
At the next step, as shown in
The triple-layered polymer film 92 is, therefore, formed without using a substrate, and the inexpensive optical waveguide having the electric conductive lines 98A for power supply can be manufactured by the inexpensive triple-layered polymer film 92 and the polymer film 98 with electric conductive lines.
In the manufacturing method according to the sixth exemplary embodiment, the first polymer film 82 to be the first cladding layer and the second polymer film 86 to be the second cladding layer are fixed to the fixing table 80 and the fixing table 84, respectively. The ultraviolet curing polymer resin with higher refractive index than the first polymer film 82 is uniformly applied to the first polymer film 82. The second polymer film 86 is overlapped with the first polymer film 82 and is irradiated with an UV ray so as to be cured. As a result, a core layer 88 is formed, and the triple-layered polymer film 92 is manufactured. Instead of this method, however, an UV curing polymer resin to be the cladding layer whose refractive index is lower than the core layer is uniformly applied to both the surfaces of the polymer film to be the core layer, and is irradiated with an UV ray so as to be cured. In such a manner, the triple-layered polymer film may be manufactured.
The examples are explained below more concretely, but the invention is not limited to these examples.
According to the manufacturing method of the first exemplary embodiment, an epoxy film (thickness: 50 μm, refractive index: 1.60) to be the core layer having high refractive index is adsorbed and stuck to the table. An acrylic UV curing resin to be the cladding layer with refractive index of 1.51 is applied with thickness of 25 μm to the epoxy film, and is irradiated with an UV ray to be cured. In such a manner, a double-layered polymer film is manufactured.
The double-polymer film is cut by a dicing saw with multi-wheel blade with accuracy of 55±5 μm from the core layer side. At this time, multi-blade, in which the blades with large outer diameter with thickness of 50 μm and blades with small outer diameter with thickness of 200 μm are combined alternately, is used.
An acrylic UV curing resin with refractive index of 1.51 is applied to the upper portion of the core layer into thickness of 25 μm, and is irradiated with an UV ray so as to be cured.
Finally, the double layered polymer film is diced by a normal blade, so that an optical waveguide is manufactured.
As a result, the inexpensive optical waveguide having a plurality of core portions in which the width of the core portions is 50 μm and a pitch is 250 μm can be manufactured by one-time cutting.
According to the manufacturing method of the first exemplary embodiment, an arton film to be the cladding layer (made by JSR, thickness: 25 μm, refractive index: 1.51) is adsorbed to be stuck to the table. An acrylic UV curing resin with refractive index of 1.59 is applied to the film into a thickness of 50 μm, and is irradiated with an UV ray so as to be cured. In such a manner, a double-layered polymer film is manufactured.
The double-layered polymer film is cut by a dicing saw with a multi-wheel blade with accuracy of 55±5 μm from the core layer side. At this time, the multi-blade, in which blades having large outer diameter and thickness of 50 μm, and blades having small outer diameter and thickness of 200 μm are combined alternately, is used.
An acrylic UV curing resin with refractive index of 1.51 is applied to the upper portion of the cut core layer into a thickness of 25 μm, and is irradiated with an UV ray so as to be cured.
Finally, the double-layered polymer film is diced by using a normal blade, so that an optical waveguide is manufactured.
As a result, the inexpensive optical waveguide, which has a plurality of core portions with width of 50 μm and with pitch of 250 μm, can be manufactured by one-time cutting.
According to the manufacturing method of the second exemplary embodiment, an epoxy film with high refractive index (thickness of 50 μm, refractive index: 1.60) to be the core layer is used. An acrylic UV curing resin with refractive index of 1.51 is uniformly applied to both surfaces of the core layer into a thickness of 20 μm. The acrylic UV curing resin is irradiated with an UV ray so as to be cured. In such a manner, a triple-layered polymer film is manufactured.
The triple-layered polymer film is cut by a dicing saw with a multi-wheel blade with accuracy of 75±5 μm. At this time, a multi-blade, in which blades with large outer diameter and thickness of 50 μand blades with small outer diameter and thickness of 200 μm are combined alternately, is used.
An acrylic UV curing resin with refractive index of 1.51 is applied to fill the concave portions, and is irradiated with an UV ray so as to be cured.
Finally, the triple-layered polymer film is diced by using a normal blade, so that an optical waveguide is manufactured.
As a result, the inexpensive optical waveguide, which has a plurality of core portions with width of 50 μm and with pitch of 250 μm, can be manufactured by one-time cutting.
According to the manufacturing method of the first exemplary embodiment, a fluorinated polyimide film to be the cladding layer (thickness of 20 μm, refractive index: 1.55) is adsorbed to be stuck to the table. An epoxy UV curing resin with refractive index of 1.62 is applied to the film into a thickness of 50 μm. The epoxy UV curing resin is irradiated with an UV ray so as to be cured. In such a manner, a double-layered polymer film is manufactured.
The double-layered polymer film is cut by a dicing saw with a multi-wheel blade with accuracy of 55±5 μm from the core layer side. At this time, the multi-blade, in which blades having large outer diameter and thickness of 50 μm, and blades having small outer diameter and thickness of 200 μm are combined alternately, is used.
A fluorinated polyamic acid whose refractive index becomes 1.55 after curing is applied to the upper portion of the cut core layer into a thickness of 10 μm, and is heated to be cured at 250° C. As a result, a polyimide film is formed.
Finally, the double-layered polymer film is diced by using a normal blade, so that an optical waveguide is manufactured.
As a result, the inexpensive optical waveguide, which has a plurality of core portions with width of 50 μm and with pitch of 250 μm, can be manufactured by one-time cutting.
According to the manufacturing method of the first exemplary embodiment, a heat-resistance olefin film to be the core layer (thickness: 50 μm, refractive index: 1.62, Tg: 280° C.) is adsorbed to be stuck to the table. An epoxy UV curing resin with refractive index of 1.55 is applied to the olefin film into a thickness of 20 μm, and is irradiated with an UV ray so as to be cured. Further, the epoxy UV curing resin is heated to 200° C. so as to be sufficiently cured. As a result, a double-layered polymer film with flexibility is manufactured.
The double-layered polymer film is cut by a dicing saw with a multi-wheel blade with accuracy of 55±5 μm from the core layer side. At this time, the multi-blade, in which blades having large outer diameter with thickness of 50 μm and blades having small outer diameter with thickness of 200 μm are combined alternately, is used.
An epoxy UV curing resin with refractive index of 1.55 is applied to the double-layered polymer film into a thickness of 20 μm, and is irradiated with an UV ray so as to be cured. The epoxy UV curing resin is further heated to 200° C. so as to be cured sufficiently. As a result, flexibility is obtained.
Finally, the double-layered polymer film is diced by using a normal blade, so that an optical waveguide is manufactured.
As a result, the inexpensive optical waveguide, which has a plurality of core portions with width of 50 μm and with pitch of 250 μm, can be manufactured by one-time cutting.
According to the manufacturing method of the first and second exemplary embodiments, an alicyclic acryl film with small volume contraction and high transparency is used as the polymer film to be the cladding layer. A high-performance optical waveguide in which deformation is less at the time of processing can be manufactured.
According to the manufacturing method of the first and second exemplary embodiments, an alicyclic olefin film with small volume contraction and high transparency is used as the polymer film to be the cladding layer. A high-performance optical waveguide in which deformation is less at the time of processing can be manufactured.
According to the manufacturing method of the first and second exemplary embodiments, an UV curing acrylic resin with small volume contraction is used as the polymer resin to be the core layer. A high-performance optical waveguide in which deformation is less at the time of processing can be manufactured.
According to the manufacturing method of the first and second exemplary embodiments, an UV curing acrylic resin with small volume contraction is used as the polymer resin to be the core layer. A high-performance optical waveguide in which deformation is less at the time of processing can be manufactured.
According to the manufacturing method of the first exemplary embodiment, an UV curing epoxy resin with small volume contraction is used as the polymer resin to be the cladding layer. A high-performance optical waveguide in which deformation is less at the time of processing can be manufactured.
According to the manufacturing method of the first exemplary embodiment, an UV curing acrylic resin with small volume contraction is used as the polymer resin to be the cladding layer. A high-performance optical waveguide in which deformation is less at the time of processing can be manufactured.
According to the manufacturing method of the first exemplary embodiment, an alicyclic acryl film with small volume contraction and high transparency is used as the polymer film to be the core layer. A high-performance optical waveguide in which deformation is less at the time of processing can be manufactured.
According to the manufacturing method of the first exemplary embodiment, an alicyclic olefin film with small volume contraction and high transparency is used as the polymer film to be the core layer. A high-performance optical waveguide in which deformation is less at the time of processing can be manufactured.
According to the manufacturing methods of the first and second exemplary embodiment, when the dicing saw with multi-blade is moved to a rotating axis direction, the core layer is processed into the core portions of the optical waveguide by plural steps of cutting. The plural core portions can be processed in a plurality of places.
According to the manufacturing methods of the first and second exemplary embodiment, in the multi-blade, the blades of large outer diameter are arranged with intervals of 10 to 300 μm so as to be assembled. That is, the blades having small outer diameter and thickness of 10 to 300 μm are assembled between the blades of large outer diameter. Since the blades with small outer diameter has a generalized thickness, the plural core portions can be processed by using the inexpensive multi-blade.
According to the manufacturing methods of the first and second exemplary embodiment, in the multi-blade, the gap between the blades with large outer diameter is adjusted by overlapping plural blade with small outer diameter. The distance between the blades with large outer diameter can be adjusted easily without using a spacer.
According to the manufacturing methods of the first and second exemplary embodiment, in the multi-blade, a length, which is obtained by adding the thickness of the blades with large outer diameter and the thickness of the blades with small outer diameter is determined as the pitch of the core portions. The plural core portions can be processed together at once.
According to the manufacturing method of the third exemplary embodiment, an epoxy film with high refractive index (thickness: 50 μm, refractive index: 1.60) to be the core layer is adsorbed to be stuck to the table. An acrylic UV curing resin with refractive index of 1.51 to be the cladding layer is uniformly applied to the core layer into a thickness of 25 μm. The acrylic UV curing resin is irradiated with an UV ray so as to be cured. In such a manner, a double-layered polymer film is manufactured.
The double-layered polymer film is cut by a dicing saw with a multi-wheel blade with accuracy of 55±5 μm from the core layer side, so that a plurality of core portions and two disposing portions are processed. At this time, the multi-blade, in which blades having large outer diameter with thickness of 50 μm and blades having small outer diameter with thickness of 200 μm are combined alternately, is used.
The two disposing portions are filled with silver paste by a dispenser, so that electric conductive lines are disposed.
An acrylic UV curing resin with refractive index of 1.51 is applied to the upper portion of the cut core layer into a thickness of 25 μm, and is irradiated with an UV ray so as to be cured.
Finally, the double layered polymer film is diced by a normal blade, so that an optical waveguide is manufactured.
As a result, the inexpensive optical waveguide, which has a plurality of core portions whose pitch is 250 μm and width is 50 μm and the electric conductive lines, can be manufactured by one-time cutting.
According to the manufacturing method of the third exemplary embodiment, an arton film to be the cladding layer (made by JSR, thickness: 25 μm, refractive index: 1.51) is adsorbed to be stuck to the table. An acrylic UV curing resin with refractive index of 1.59 is applied to the film into a thickness of 50 μm, and is irradiated with an UV ray so as to be cured. In such a manner, a double-layered polymer film is manufactured.
The double-layered polymer film is cut by a dicing saw with a multi-wheel blade with accuracy of 55±5 μm from the core layer side, so that a plurality of core portions and two disposing portions are processed. At this time, the multi-blade, in which blades having large outer diameter and thickness of 50 μm, and blades having small outer diameter and thickness of 200 μm are combined alternately, is used.
Copper lines are constructed on the two disposing portions, respectively, so that electric conductive lines are disposed.
An acrylic UV curing resin with refractive index of 1.51 is applied to the upper portion of the cut core layer into a thickness of 25 μm, and is irradiated with an UV ray so as to be cured.
Finally, the double layered polymer film is diced by a normal blade, so that an optical waveguide is manufactured.
As a result, the inexpensive optical waveguide, which has a plurality of core portions whose pitch is 250 μm and width is 50 μm and the electric conductive lines, can be manufactured by one-time cutting.
According to the manufacturing method of the fifth exemplary embodiment, an epoxy film with high refractive index (thickness of 50 μm, refractive index: 1.60) to be the core layer is used. An acrylic UV curing resin with refractive index of 1.51 is uniformly applied to both surfaces of the core layer into a thickness of 20 μm. The acrylic UV curing resin is irradiated with an UV ray so as to be cured. In such a manner, a triple-layered polymer film is manufactured.
The triple-layered polymer film is cut by a dicing saw having a multi-wheel blade with accuracy of 75±5 μm, so that a plurality of core portions and two disposing portions are processed. At this time, a multi-blade, in which blades having large outer diameter and thickness of 50 μm, and blades having small outer diameter and thickness of 200 μm are combined alternately, is used.
Copper lines are constructed on the two disposing portions, respectively, so that electric conductive lines are disposed.
An acrylic UV curing resin with refractive index of 1.51 is applied so as to fill cut concave portions, and is irradiated with an UV ray so as to be cured.
Finally, the triple-layered polymer film is diced by a normal blade, so that an optical waveguide is manufactured.
As a result, the inexpensive optical waveguide, which has a plurality of core portions whose pitch is 250 μm and width is 50 μm and the electric conductive lines, can be manufactured by one-time cutting.
According to the manufacturing method of the fourth exemplary embodiment, an arton film to be the cladding layer (made by JSR, thickness: 25 μm, refractive index: 1.51) is adsorbed to be stuck to the table. An acrylic UV curing resin with refractive index of 1.59 is applied to the film into a thickness of 50 μm, and is irradiated with an UV ray so as to be cured. In such a manner, a double-layered polymer film is manufactured.
The double-layered polymer film is cut by a dicing saw with a multi-wheel blade with accuracy of 55±5 μm from the core layer side, so that a plurality of core portions are processed. At this time, the multi-blade, in which blades having large outer diameter and thickness of 50 μm, and blades having small outer diameter and thickness of 200 μm are combined alternately, is used.
An acrylic UV curing resin with refractive index of 1.51 is applied to the upper portion of the cut core layer into a thickness of 25 μm.
An arton film (made by JSR, thickness: 25 μm, refractive index: 1.51) on which silver power supply lines are patterned by vacuum evaporation and etching is laminated as a polymer film with electric conductive lines to the applied acrylic UV curing resin. Thereafter, the acrylic UV curing resin is irradiated with an UV ray so as to be cured.
Finally, the double layered polymer film is diced by a normal blade, so that an optical waveguide is manufactured.
As a result, the inexpensive optical waveguide, which has a plurality of core portions whose pitch is 250 μm and width is 50 μm and the electric conductive lines, can be manufactured by one-time cutting.
According to the manufacturing method of the fourth exemplary embodiment, an arton film to be the cladding layer (made by JSR, thickness: 25 μm, refractive index: 1.51) is adsorbed to be stuck to the table. An acrylic UV curing resin with refractive index of 1.59 is applied to the film into a thickness of 50 μm, and is irradiated with an UV ray so as to be cured. In such a manner, a double-layered polymer film is manufactured.
The double-layered polymer film is cut by a dicing saw with a multi-wheel blade with accuracy of 55±5 μm from the core layer side, so that a plurality of core portions are processed. At this time, the multi-blade, in which blades having large outer diameter and thickness of 50 μm, and blades having small outer diameter and thickness of 200 μm are combined alternately, is used.
An acrylic UV curing resin with refractive index of 1.51 is applied to the upper portion of the cut core layer into a thickness of 25 μm.
An arton film (made by JSR, thickness: 25 μm, refractive index: 1.51) on which gold power supply lines are patterned by sputtering and etching is laminated as a polymer film with an electric conductive lines to the applied acrylic UV curing resin. Thereafter, the acrylic UV curing resin is irradiated with an UV ray so as to be cured.
Finally, the double layered polymer film is diced by a normal blade, so that an optical waveguide is manufactured.
As a result, the inexpensive optical waveguide, which has a plurality of core portions whose pitch is 250 μm and width is 50 μm and the electric conductive lines, can be manufactured by one-time cutting.
According to the manufacturing methods of the third to sixth exemplary embodiments, metal paste is applied by a dispenser, so that electric conductive lines for power supply are disposed. Since this is a general method, the electric conductive liens can be disposed inexpensively.
According to the manufacturing methods of the third to sixth exemplary embodiments, an electric conductive member is adhere by a sputtering method, so that electric conductive lines for power supply are disposed. Since a generalized device can be used, the electric conductive lines can be disposed inexpensively.
According to the manufacturing methods of the third to sixth exemplary embodiments, an alicyclic acryl film with small volume contraction and high transparency is used as the polymer film to be the cladding layer. A high-performance optical waveguide in which deformation is less at the time of processing can be manufactured.
According to the manufacturing methods of the third to sixth exemplary embodiments, an alicyclic olefin film with small volume contraction and high transparency is used as the polymer film to be the cladding layer. A high-performance optical waveguide in which deformation is less at the time of processing can be manufactured.
According to the manufacturing methods of the third to sixth exemplary embodiments, an UV curing epoxy resin with small volume contraction is used as the polymer resin to be the core layer. A high-performance optical waveguide in which deformation is less at the time of processing can be manufactured.
According to the manufacturing method of the third to sixth exemplary embodiments, an UV curing acrylic resin with small volume contraction is used as the polymer resin to be the core layer. A high-performance optical waveguide in which deformation is less at the time of processing can be manufactured.
According to the manufacturing methods of the third and fourth exemplary embodiments, an UV curing epoxy resin with small volume contraction is used as the polymer resin to be the cladding layer. A high-performance optical waveguide in which deformation is less at the time of processing can be manufactured.
According to the manufacturing methods of the third and fourth exemplary embodiments, an UV curing acrylic resin with small volume contraction is used as the polymer resin to be the cladding layer. A high-performance optical waveguide in which deformation is less at the time of processing can be manufactured.
According to the manufacturing methods of the third and fourth exemplary embodiments, an alicyclic acryl film with small volume contraction and high transparency is used as the polymer film to be the core layer. A high-performance optical waveguide in which deformation is less at the time of processing can be manufactured.
According to the manufacturing methods of the third and fourth exemplary embodiments, an alicyclic olefin film with small volume contraction and high transparency is used as the polymer film to be the core layer. A high-performance optical waveguide in which deformation is less at the time of processing can be manufactured.
According to the manufacturing method of the third to sixth exemplary embodiments, when the dicing saw with multi-blade is moved to the rotating axis direction, the core layers are processed into core portions of the optical waveguide by plural steps of cutting. The plural core portions can be processed in plural places.
According to the manufacturing methods of the third to sixth exemplary embodiments, in the multi-blade, the blades of large outer diameter are arranged with an interval of 10 to 300 μm so as to be assembled. That is, the blades having small outer diameter and thickness of 10 to 300 μm are assembled between the blades of large outer diameter. Since the blades with small outer diameter has a generalized thickness, the plural core portions can be processed by using the inexpensive multi-blade.
According to the manufacturing methods of the third to sixth exemplary embodiments, in the multi-blade, the gap between the blades with large outer diameter is adjusted by overlapping the plural blades with small outer diameter. The distance between the blades with large outer diameter can be adjusted easily without using a spacer.
According to the manufacturing methods of the third to sixth exemplary embodiments, in the multi-blade, a length, which is obtained by adding the thickness of the blades with large outer diameter and the thickness of the blades with small outer diameter is determined as the pitch of the core portions. The plural core portions can be processed together at once.
Number | Date | Country | Kind |
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2005-336283 | Nov 2005 | JP | national |
2005-336284 | Nov 2005 | JP | national |