1. Field of the Invention
The invention relates generally to waveguide equipment and a polymer waveguide for optical communications.
2. Background Art
In a connected portion or an end portion of an optical fiber cable for optical communications, waveguide equipment is used to connect the end of one optical fiber cable to, for example, another optical fiber cable, a light projection device, a photo detector, etc. So, it is requested that such waveguide equipment can be produced with low cost and be suitable for a mass production, as the use of the optical communication, which can transmit large capacity data with high-speed, has increased in recent years.
As a result, a polymer waveguide using a high molecular compound (polymer) is suggested for the waveguide. When the waveguide equipment is assembled by integrating the polymer waveguide with the optical fiber made of glass or polymer, an end surface of the polymer waveguide is integrated with an end surface of the fiber guide which holds the optical fiber using high molecular glue.
The optical fiber or the optical fiber arrays are made of silica glass. So, adhesion is high between the glue and the optical fiber or the optical fiber arrays. This is because glass has many OH radicals and has high affinity with glue; so the glue is spread on the surface of the glass and bonds with the OH radicals on the surface of glass by hydrogen bond or van der Waals forces. And, if UV hardening glue is applied on a silane coupling agent on the glass, adhesion can be improved by a chemical bond. But, adhesion between the polymer waveguide and the glue is not stronger than that between the glass and the glue. Because most of the association of each atom in highly-polymer compounds are connected by hardening entirely, and there are few OH radicals on the surface of the waveguide to bond with the glue. So, the hydrogen bonding strength, the van der Waals forces, and the chemical bonding strength become weak. Moreover, unevenness watched with a numerator level appears to an end surface of the waveguide, and all of the OH radicals expressed in an end surface of the waveguide do not bond with glue. So, this adhesive strength between the polymer waveguide and the fiber guide is weak, and it is easy to exfoliate by high temperature and high air moisture. Thus, there is a problem in the reliability of the adhesive strength.
However, degradation of adhesive strength is only prevented by preventing the invasion of moisture and the exfoliation from the outer peripheral portion of the bonding surface. These methods could not improve adhesive strength with the waveguide and the optical fiber fundamentally.
Embodiments of the present invention improve the adhesive strength between the polymer waveguide and the optical fiber, and provide waveguide equipment which has a high reliability for moisture and temperature change.
In one embodiment of the present invention, waveguide equipment comprises a polymer waveguide having a core and cladding, and an optical fiber which is connected to an end surface of the polymer waveguide with glue and which is optically connected with the core, wherein an oxide film formed between at least one end surface of the polymer waveguide or the optical fiber and the glue.
In an aspect of the present invention, a polymer waveguide comprises a core and a cladding of the polymer waveguide being formed on a substrate made of mineral matter materials, wherein an oxide film formed between at least one surface faced each other of the substrate or the cladding, and the surface of the cladding and the substrate connected via the oxide film with glue.
In one embodiment of the present invention, a polymer waveguide comprises the polymer waveguide having a core and cladding, wherein an oxide film formed on the polymer waveguide and a metal film formed on the oxide film.
As much as possible, the above mentioned constituent elements of the present invention can be combined arbitrarily. Other aspects and advantages of the invention will be apparent from the following description and the appended claims.
The present invention is explained specifically below with reference to specific embodiments. These embodiments are merely examples, and the present invention is not limited to only the embodiments described below.
Specific embodiments of the present invention are explained in detail below with reference to the figures. These embodiments are merely examples and the present invention is not limited to the specific embodiments explained below.
The ultraviolet radiation hardening type transparent resin is desirable as the resin to form the over and under cladding 26, 24 and the core 25, but the heat curing type transparent resin can also be used. Similarly, PMMA (polymethylmethacrylate), photo-PCB (photo-curing type polychlorinated biphenyl), alicyclic epoxy resin, photosensitive cationic polymerization initiator, acrylate resin (containing Si and F), photosensitive free-radical polymerization initiator, and fluoridated polyimide (these resins are not limited to a photo-curing type.) can be used as the transparent resin to form the over and under cladding 26, 24 and the core 25. A reproduction method with a stamper is preferable to form the under cladding 24, but hot pressing, etching, and injection molding can be used to form the under cladding 24.
A lot of the waveguide 21 is produced on a glass wafer at one time in a mass production, which improves productivity. The many optical waveguides 21 produced on the wafer are cut by dicing methods, and they are split into a piece of the waveguide 21. At this time, the end surface of each waveguide 21 is ground, and both end surfaces of the core 25 exposed may be finished smoothly.
After that, as shown in
In this production process, molecules consisting of the oxide film 27 arrive at the end surface of the waveguide 21 with kinetic energy by the sputtering method and the evaporation method. So, the molecules are bonded with more OH radicals by ionic bonding or chemical bonding at the end surface of the waveguide 21. As a result, the exfoliative strength between the waveguide 21 and the oxide film 27 can be raised as compared to glue applied on the end surface of the waveguide directly.
Silicon oxide film for the oxide film 27 is preferable, but the transparent oxide film such as even aluminum, magnesium, or SiON are preferable if the coupling efficiency between the optical fiber and the waveguide 21 does not become decreased. The oxide film in which the number of oxygen atoms is less than the most stable stoichiometric composition is desirable. For example, SiOx (x=1 to 1.5), which has smaller oxygen content than SiO2, is desirable as the silicon oxide film. The film that has a smaller ratio of an oxygen atom than Al2O3 is preferable as the aluminum oxide film.
It is desirable that the thickness of the oxide film 27 is thinner than 4000 Å. That is because it prevents degradation of an optical transmission rate in the oxide film 27 and crack outbreak by internal stress of the oxide film 27. In addition, it is desirable that the thickness of oxide film 27 is thicker than 500 Å. That is because it prevents water or steam from getting into the waveguide 21 through the oxide film 27. In addition, it is necessary that the oxide film 27 be layered by a cold temperature grown method of less than 200 degrees Celsius in order to not make the waveguide 21 deteriorate because it is a deposition on the resin of the waveguide 27 that the oxide film 27 is layered. In addition, a substrate temperature in a deposition equipment should be kept not more than 100 degrees Celsius when the oxide film is layered more than 2000 Å to prevent cracks. So, the quality of the oxide film can be improved.
As shown in
As shown in
If the oxide film 27 is formed on the end surface of the waveguide 21, the adhesion between the oxide film 27 and the glue 37 improves and the adhesion between the oxide film 27 and the waveguide 21 also improves. So, the adhesive strength improves between the waveguide 21 and the fiber guide 22, 23. However, if the SiO2 that has a stable composition is used as the oxide film 27, the exfoliative strength between the oxide film 27 and the glue 37 becomes lower and the exfoliative strength between the oxide film 27 and the waveguide 21 also becomes lower. So, the adhesive strength becomes lower between the waveguide 21 and the fiber guide 22, 23. On the other hand, if SiOx (1≦x≦1.5) that has a composition ratio of an oxygen atom which is smaller is used as the oxide film 27, the exfoliative strength between the oxide film 27 and the glue 37 can be improved and the exfoliative strength between the oxide film 27 and the waveguide 21 can be improved. Thus, the adhesive strength can be made higher between the waveguide 21 and the fiber guide 22, 23.
Secondly, the adhesive strength improves when an oxide film 27 that has a composition ratio of an oxygen atom which is smaller is formed on the end face of the waveguide 21. When SiO2 is formed as the oxide film 27 on the resin surface of the waveguide 21, that resin and the oxide film 27 are bonded because the OH radicals of the resin surface of the waveguide 21 and of the oxide film 27 bond chemically. However, SiO2 is a stable composition and bonding of each atom is saturated. Thus, there is less excess binding residue in SiO2. SiO2 and the resin bond chemically through an oxygen atom included in the OH radicals on the resin surface of waveguide 21, but the exfoliative strength is low between the waveguide 21 and the oxide film 27 for lack of binding residue with chemical bond.
When SiO2 is formed as the oxide film 27, the bonding between the glue 37 and the oxide film 27 is also the same way. As shown in
On the other hand, the bonding state is unstable for unsaturated bonding by lack of an oxygen atom in SiOx (1≦x≦1.5). Therefore, many OH radicals appear on the surface of SiOx because an atmospheric H atom is bonded to SiOx, the oxide film 27. As a result, the OH radicals in SiOx react to the OH radicals in the waveguide 21 as follows.
OH−+OH−→O2−+H2O
So, many OH radicals bond chemically through O atoms. Therefore, the exfoliative strength between the waveguide 21 and the oxide film 27 can be improved by using SiOx (1≦x≦1.5) as the oxide film 27.
When SiOx (1≦x≦1.5) is formed as the oxide film 27, the bonding between the glue 37 and the oxide film 27 is also the same way. The bonding state of the oxide film 27 is unstable for unsaturated bonding by lack of an oxygen atom. Therefore, as shown in
As a result, both the exfoliative strength between the oxide film 27 and the waveguide 21 and the exfoliative strength between the oxide film 27 and the glue 37 can be improved by using SiOx (1≦x≦1.5) as the oxide film 27. Furthermore, the adhesive strength between the waveguide 21 and the glue 37 can be improved.
In addition, it is known that internal stress of SiOx (1≦x≦1.5) film is smaller than that of SiO2 film. For example, internal stress of SiO1.3 is ⅕ compared with SiO2 film. According to an experiment, SiO2 film was completely damaged when a sample consisting of polymer waveguide formed on a glass substrate, SiO2 film formed thereupon, and a glass substrate bonded thereupon, was exposed for 20 hours to high temperature and high humidity condition. In contrast, SiO1.3 film was not damaged as only some wrinkles occurred to the oxide film when a sample consisting of polymer waveguide formed on a glass substrate, SiO1.3 film formed thereupon, and a glass substrate bonded thereupon, was exposed for 20 hours to high temperature and high humidity condition. Therefore, the waveguide equipment 20 which is hard to deteriorate under high temperature and high humidity condition, superior in reliability, and having high adhesive strength can be produced using SiOx (1≦x≦1.5) as oxide film 27.
Next, two kinds of samples of the waveguide 21 in which the resin is easy to change its characteristic at high temperature and high humidity condition are presented. As shown in
A break down test was done with the waveguide equipment 20 produced above. The waveguide equipment 20 was put into a PCT (Pressure Cooker Testing machine) at the break down test. As a result, it is made sure that adhesive strength was kept without damaging the oxide film 27 which was formed on the end of the waveguide 21 even after more than 50 hours of testing.
In the embodiment described above, the exemplary waveguide was single mode, but a multimode waveguide that has the same structure can be made using the same production method.
In this embodiment, the oxide film 27 is formed on the end surface of the waveguide 21 made of organic materials and mineral matter materials. The end surface of the waveguide 21 formed oxide film 27 and the fiber guide 22 and 23 are adhered with the glue 37. Even this embodiment, when the SiO2 film is formed as the oxide film 27, the oxide film 27 is damaged after exposed in high temperature and high humidity condition for a long time. On the other hand, if SiOx (1≦x≦1.5) film is formed as the oxide film 27, the internal stress of oxide film 27 shrink and the oxide film 27 is not damaged after exposed in high temperature and high humidity condition for a long time.
In the waveguide 21, as shown
In the above embodiment, the waveguide equipment is coupled to an optical fiber on both sides of the waveguide. Those skilled in the art will appreciate that an optical transceiver, such as a photo detector or a light projection device, may be connected to the waveguide equipment. Also, various kinds of forms such as an optical coupler, a WDM coupler, a VOA (a variable optical attenuator), an optical switch, and a multimode waveguide device may be used.
While the invention has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the invention as disclosed herein. Accordingly, the scope of the invention should be limited only by the attached claims.
Number | Date | Country | Kind |
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JP2004-039970 | Feb 2004 | JP | national |