JP2006079123A - Manufacturing method of microlens array - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of a microlens array that facilitates alignment with other optical components. <P>SOLUTION: A microlens array LA<SB>11</SB>has a structure in which, on a translucent substrate 10, convex lenses L<SB>11</SB>-L<SB>14</SB>are installed on one principal surface while convex lenses L<SB>21</SB>-L<SB>24</SB>are installed on the other principal surface in a manner oppositely facing the convex lenses L<SB>11</SB>-L<SB>14</SB>respectively, a biconvex lens is formed for each pair of oppositely facing lenses. On one principal surface of the substrate 10, there are provided fitting hole forming members 38A, 38B through a selective plating process. A microlens array LA<SB>12</SB>has a structure in which, on a translucent substrate 50, convex lenses L<SB>51</SB>-L<SB>54</SB>are installed on one principal surface while fitting pins 62A, 62B are installed on the other principal surface through the selective plating process, a microlens array is formed by combinedly fitting the pins 62A, 62B in the holes of the members 38A, 38B. On one principal surface of the substrate 50, there is provided, through the selective plating process, a fitting hole forming member 60 having holes M<SB>1</SB>-M<SB>4</SB>for fitting optical fibers F<SB>1</SB>-F<SB>4</SB>respectively. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a method of manufacturing a microlens array used for optical communication or the like.

  Conventionally, as a microlens array, the one shown in FIG. 30 is known (see, for example, Patent Document 1), and FIGS. 27 to 29 show a manufacturing method of this microlens array.

  In the process shown in FIG. 27, a quartz glass layer 4 having a thickness of 50 μm is formed on one main surface of a silicon substrate 3 having a thickness of 500 μm, and then a spherical convex portion is formed on the quartz glass layer 4 according to a desired lens pattern. Thus, the resist layers 5a to 5c are formed by photolithography and heat treatment.

  In the process of FIG. 28, the resist layers 5a to 5c and the quartz glass layer 4 are etched by RIE (reactive ion etching) to transfer the lens patterns of the resist layers 5a to 5c onto the upper surface of the quartz glass layer 4. The convex lenses 4a to 4c corresponding to the resist layers 5a to 5c, respectively, are formed. The diameter of each convex lens can be 60 μm. Thereafter, a resist layer 6 having holes 6a to 6c for forming connection holes on the other main surface of the substrate 3 is formed by photolithography.

  In the process of FIG. 29, the connection holes 3a to 3c are formed on the silicon substrate 3 so as to face the convex lenses 4a to 4c, respectively, by dry etching using the resist layer 6 as a mask. In each connection hole, the depth can be 500 μm and the diameter can be 125 μm.

FIG. 30 shows a state in which the optical fiber 7 is inserted into the connection hole 3a in the microlens array of FIG. 29. The depth of the connection hole 3a is more than twice the diameter of the connection hole 3a. Is securely held in the connection hole 3a.
JP-A-9-90162

  According to the above prior art, each convex lens such as 4a formed on one main surface of the substrate 3 constitutes a plano-convex lens because the other main surface of the substrate 3 is flat. The lens action is based on the light refraction phenomenon according to Snell's law, and the problem of a large numerical aperture (NA) cannot be obtained with a plano-convex lens configuration in which a lens spherical surface is provided only on one main surface of the substrate 3. There is.

  In general, in order to realize a high NA lens and a low aberration lens, it is known to form a combination lens by arranging several lenses in the optical axis direction (see, for example, Japanese Patent Application Laid-Open No. 8-33489). In the combination lens, the optical characteristics are improved, but there is a problem that the lens configuration is enlarged and the optical axis adjustment between the lenses is not easy. In particular, in a microlens array in which a plurality of microlenses are arrayed, high-precision optical axis adjustment (alignment) is performed for all lenses when combined with other optical components such as optical fiber arrays and microlens arrays. ) Is difficult to perform, and an easy-to-use alignment structure has not been proposed.

  An object of the present invention is to provide a novel method for manufacturing a microlens array that can easily perform high-precision alignment or positioning when combined with other optical components.

The manufacturing method of the first microlens array according to the present invention is as follows:
Preparing a translucent substrate having one and the other main surfaces facing each other;
Transferring a lens pattern to one main surface of the translucent substrate by etching to form a plurality of first convex lenses;
Forming a plurality of second convex lenses by transferring a lens pattern to the other main surface of the translucent substrate so as to face the plurality of first convex lenses, respectively.
A plurality of plating base films so as not to overlap a lens arrangement region including a plurality of convex lenses formed on the one main surface on at least one main surface of the one main surface and the other main surface of the translucent substrate Forming a step;
Forming a plurality of fitting pins on the plurality of plating base films by selective plating.

  According to the manufacturing method of the first microlens array, a plurality of first convex lenses are formed on one main surface of the translucent substrate, and are opposed to the plurality of first convex lenses on the other main surface of the translucent substrate. Since a plurality of second convex lenses are formed, a double-side convex lens is formed for each pair of opposed lenses, and a large NA is obtained.

  In the manufacturing method of the first microlens array, at least one main surface of the one and other main surfaces is not overlapped with a lens arrangement region including a plurality of convex lenses formed on the one main surface. Since the mating pins are formed by selective plating, when mating the microlens array to other optical components such as an optical fiber array or microlens array, the mating pins are used to easily achieve submicron order accuracy. Alignment can be performed.

The manufacturing method of the second microlens array according to the present invention is as follows:
Preparing a translucent substrate having one and the other main surfaces facing each other;
Transferring a lens pattern to one main surface of the translucent substrate by etching to form a plurality of convex lenses;
Forming a plurality of plating base films on one main surface or the other main surface of the translucent substrate so as not to overlap a lens arrangement region including a plurality of convex lenses formed on the one main surface;
Forming a plurality of fitting pins on the plurality of plating base films by selective plating.

  According to the manufacturing method of the second microlens array, a plurality of convex lenses are formed on one main surface of the translucent substrate, and a plurality of convex lenses are formed on one main surface of one or the other main surface of the translucent substrate. Since the fitting pin is formed by selective plating so as not to overlap the lens arrangement region including the convex lens, the fitting pin is used when the microlens array is coupled to another optical component such as an optical fiber array or a microlens array. Positioning can be easily performed with submicron order accuracy by fitting.

The method for producing the third microlens array according to the present invention is as follows:
Preparing a translucent substrate having one and the other main surfaces facing each other;
Transferring a lens pattern to one main surface of the translucent substrate by etching to form a plurality of first convex lenses;
Forming a plurality of second convex lenses by transferring a lens pattern to the other main surface of the translucent substrate so as to face the plurality of first convex lenses, respectively.
A plurality of plating base films so as not to overlap a lens arrangement region including a plurality of convex lenses formed on the one main surface on at least one main surface of the one main surface and the other main surface of the translucent substrate Forming a step;
Forming a plurality of fitting hole forming members each having a fitting hole on the plurality of plating base films by selective plating.

  According to the manufacturing method of the third microlens array, a plurality of first convex lenses are formed on one main surface of the translucent substrate and are opposed to the plurality of first convex lenses on the other main surface of the translucent substrate. Since a plurality of second convex lenses are formed, a double-side convex lens is formed for each pair of opposed lenses, and a large NA is obtained.

  In the third microlens array manufacturing method, at least one main surface of the one and other main surfaces is not overlapped with a lens arrangement region including a plurality of convex lenses formed on the one main surface. Since the fitting hole forming member is formed by selective plating, when the microlens array is coupled to another optical component such as an optical fiber array or a microlens array, the fitting hole forming member is used for fitting. Positioning can be easily performed with submicron order accuracy.

The method for producing the fourth microlens array according to the present invention is as follows:
Preparing a translucent substrate having one and the other main surfaces facing each other;
Transferring a lens pattern to one main surface of the translucent substrate by etching to form a plurality of convex lenses;
Forming a plurality of plating base films on one main surface or the other main surface of the translucent substrate so as not to overlap a lens arrangement region including a plurality of convex lenses formed on the one main surface;
Forming a plurality of fitting hole forming members each having a fitting hole on the plurality of plating base films by selective plating.

  According to the fourth method for producing a microlens array, a plurality of convex lenses are formed on one main surface of the translucent substrate, and a plurality of convex lenses are formed on one main surface of one or the other main surface of the translucent substrate. Since the fitting hole forming member is formed by selective plating so as not to overlap the lens arrangement area including the convex lens, the fitting hole is formed when the microlens array is coupled to another optical component such as an optical fiber array or a microlens array. Positioning can be easily performed with submicron-order accuracy by fitting using the fitting hole of the forming member.

  In the third or fourth microlens array manufacturing method, when the fitting hole forming member is formed by selective plating, the fitting hole is formed using a delay in plating growth near the inner wall of the fitting hole. It can be easily formed so as to increase in size as it goes from the inside to the outside, and in this way, the fitting becomes easy.

The fifth microlens array manufacturing method according to the present invention is:
Preparing a translucent substrate having one and the other main surfaces facing each other;
Transferring a lens pattern to one main surface of the translucent substrate by etching to form a plurality of convex lenses;
Forming a plating base film on one main surface of the translucent substrate so as to expose at least central portions of the plurality of convex lenses, respectively;
Forming a fitting hole forming member having a plurality of optical fiber fitting holes respectively corresponding to the exposed portions of the plurality of convex lenses on the plating base film by a selective plating process.

  According to the fifth microlens array manufacturing method, a plurality of optical fibers can be easily coupled to the microlens array simply by fitting the plurality of optical fibers into the plurality of optical fiber fitting holes. The fiber is positioned with high accuracy on the corresponding convex lens through the corresponding optical fiber fitting hole. When forming the fitting hole forming member by selective plating, the size increases as the optical fiber fitting hole is moved outward from the inside by utilizing the delay of plating growth near the inner wall of the optical fiber fitting hole. It can be easily formed so as to increase, and in this way, the fitting becomes easy.

  According to the present invention, the lens pattern is transferred to both main surfaces of the translucent substrate by etching to form a plurality of convex lenses on both sides, so that an effect of realizing a microlens array having a large NA can be obtained.

  In addition, when forming a plurality of convex lenses on one or both main surfaces of the translucent substrate, a fitting pin or a fitting hole forming member is formed on one of the main surfaces by a selective plating process. The effect of being able to easily perform alignment with submicron order accuracy by fitting using a fitting pin or a fitting hole when coupled with another optical component such as a microlens array.

  Furthermore, when forming a plurality of convex lenses on one main surface of the translucent substrate, a fitting hole formation having a plurality of optical fiber fitting holes that respectively expose at least the center portions of the plurality of convex lenses is formed on the lens forming surface. Since the member is provided, it is possible to easily position the optical fiber with submicron order accuracy when a plurality of optical fibers are coupled to the microlens array.

  FIG. 1 shows a microlens array according to an embodiment of the present invention. FIG. 13 is a sectional view taken along a line connecting aa ′ line, XX ′ line, and bb ′ line in FIG. Shown in However, in FIG. 1, the components denoted by reference numerals 24, 30 </ b> A, and 30 </ b> B in FIG. 13 are omitted for simplicity.

The microlens array LA ₁ forms a plurality of convex lenses L ₁₁ , L ₁₂ , L ₁₃ ... By transferring a lens pattern to one main surface of a translucent substrate 10 made of a square quartz substrate, for example, by etching. A lens pattern is transferred to the other main surface of the substrate 10 by etching to form a plurality of convex lenses L ₂₁ , L ₂₂ , L ₂₃ ... So as to face the plurality of convex lenses L ₁₁ , L ₁₂ , L ₁₃ . It is. In the substrate 10, the length A of one side can be 3 mm, and the thickness t can be 200 μm (or less). As an example, 4 × 4 convex lenses L ₁₁ , L ₁₂ , L ₁₃ ... Can be arranged in a matrix, and the same applies to convex lenses L ₂₁ , L ₂₂ , L ₂₃ .

On one main surface of the substrate 10, fitting pins 12A and 12B are provided so as not to overlap a lens arrangement region including the convex lenses L ₁₁ , L ₁₂ , L ₁₃ . The fitting pins 12A and 12B are provided diagonally on one main surface of the substrate 10 as an example, but may be provided at other positions or three or more. Each fitting pin can be formed easily and with high precision by a plating process to be described later.

According to the micro lens array LA ₁ shown in FIG. 1, a pair of so either side convex lens is configured for each opposing lens, large NA as compared with the plano-convex lens type micro lens array shown in FIG. 27 to 30 Is obtained. The optical fiber array microlens array LA _1, upon binding to the other optical components such as a micro lens array, dowel pin 12A, 12B align with the precision of easily submicron order by engagement by (tone Core).

  2 to 13 show an example of the manufacturing method of the microlens array in FIG. 1, and the same parts as those in FIG.

In the process of FIG. 2, a fixed substrate 20 to which a light transmitting substrate 10 made of a quartz substrate is fixed by adhesion or the like is prepared. Then, resist layers S _{1 to} S ₄ are formed on the upper surface of the substrate 10 by photolithography and heat treatment according to a desired lens pattern. Each resist layer is formed so as to form a spherical convex portion.

In step Fig. 3, RIE method with the resist layer _S 1 to S ₄ and the upper surface on the resist layer _S 1 to S resist layer _S 1 to transfer the lens pattern ₄ to the substrate 10 by an etching process performed on the substrate 10 Convex lenses L _{21 to} L ₂₄ corresponding to S ₄ are formed.

In the process of FIG. 4, a resist layer 22 is applied to the upper surface of the substrate 10 so as to cover the convex lenses L _{21 to} L ₂₄ . In the resist layer 22, an alignment mark forming hole 22 a is formed by exposure / development processing so as not to overlap the lens arrangement region including the convex lenses L _{21 to} L ₂₄ .

  In the process of FIG. 5, a metal film 24A is formed by covering the resist layer 22 on the upper surface of the substrate 10 and depositing a metal such as Cr or Ni—Fe alloy by sputtering. The metal film 24 </ b> A adheres to the upper surface of the substrate 10 through the hole 22 a of the resist layer 22.

  In the process of FIG. 6, the resist layer 22 and the metal film 24A thereon are removed by lift-off processing. As a result, the portion 24 of the metal film 24A attached to the upper surface of the substrate 10 remains as an alignment mark.

  In the process of FIG. 7, after peeling the substrate 10 from the fixed substrate 20, the substrate 10 is turned over so that the alignment mark 24 faces downward, and the upper surface of the substrate 10 is fixed to the fixed substrate 26 by adhesion or the like. As the fixed substrate 26, the substrate 20 may be used, or another substrate may be used.

In the process of FIG. 8, convex lenses L _{11 to} L ₁₄ are formed on the upper surface (original lower surface) of the substrate 10 by executing the lens forming process in the same manner as described above with reference to FIGS. At this time, four resist layers (corresponding to S _{4 to} S ₁ in FIG. 2) are formed so as to face the convex lenses L _{21 to} L ₂₄ by performing photolithography using the alignment marks 24. Convex lenses L _{11 to} L ₁₄ are formed corresponding to these resist layers.

  In the step of FIG. 9, a resist layer 28 having holes 28A and 28B respectively corresponding to two desired plating base films is formed on the upper surface of the substrate 10 by photolithography. Even in the photolithography process at this time, the positions of the holes 28A and 28B can be accurately determined using the alignment mark 24. A metal film 30 made of a Ni—Fe alloy is formed on the upper surface of the substrate 10 by a sputtering method so as to cover the resist layer 28. The metal film 30 adheres to the upper surface of the substrate 10 through the holes 28A and 28B of the resist layer 28.

  In the process of FIG. 10, the resist layer 28 and the metal film 30 thereon are removed by a lift-off process. As a result, the portions 30A and 30B of the metal film 30 adhering to the upper surface of the substrate 10 remain as the plating base film.

  In the process of FIG. 11, resist layers 32A and 32B having holes 32a and 32b respectively corresponding to two desired fitting pins are formed on the plating base films 30A and 30B by photolithography. Then, the Ni—Fe alloy selective plating process is performed using the resist layers 32A and 32B as masks to form the fitting pins 12A and 12B made of the Ni—Fe alloy. As an example, each fitting pin can have a length of 120 μm and a diameter of 125 μm.

In the process of FIG. 12, the resist layers 32A and 32B are removed by chemical treatment or the like. Thereafter, in the step of FIG. 13, to obtain a micro lens array LA ₁ separates the substrate 10 from the fixed substrate 26. In the microlens array LA ₁ , convex lenses L _{11 to} L ₁₄ are formed on one main surface of the substrate 10 and fitting pins 12A and 12B are formed through plating base films 30A and 30 respectively. On the other main surface, convex lenses L _{21 to} L ₂₄ are formed to face the convex lenses L _{11 to} L ₁₄ , respectively, and an alignment mark 24 is formed.

According to the manufacturing method of the microlens array described above, the convex lenses L _{11 to} L ₁₄ , L _{21 to} L ₂₄ and the fitting pins 12A and 12B can be manufactured with a precision of submicron order and with a high yield.

In the above embodiment, the one main surface of the substrate 10 is provided engaging pins 12A, the 12B, an example is shown of using a micro lens array LA ₁ as male microlens array, one of the main substrate 10 the surface provided with the fitting hole-forming member having a fitting hole for fitting fitting pins 12A, the 12B, it is also possible to use a microlens array LA ₁ as a female side microlens array. 14 and 15 show an example of a fitting hole forming member creation method.

In the process of FIG. 14, following the process of FIG. 10, resist layers A ₁ and B ₁ are formed on the plating base films 30A and 30B by photolithography, respectively. The resist layers A ₁ and B ₁ are formed in a circular shape, for example, corresponding to the fitting hole pattern so as to have a size slightly larger than a desired fitting hole. The resist layers A ₁ and B ₁ are for imparting outward shapes to the openings of the fitting holes.

Next, resist layers A ₂ and B ₂ are formed on the resist layers A ₁ and B ₁ , and resist layers A ₃ and B ₃ are formed on the plating base films 30A and 30B by photolithography. The resist layers A ₂ and B ₂ are formed in a columnar shape so as to have a smaller diameter than the resist layers A ₁ and B ₁ corresponding to the desired fitting holes, respectively. The resist layers A ₃ and B ₃ are respectively resist layers layer _a 1, separated from the _{B 1} by a predetermined distance to form a for example annular so as to surround the resist layer _a 1, _{B 1.} The resist layers A ₃ and B ₃ are not limited to an annular shape, and may have a polygonal frame shape or the like.

Thereafter, by performing selective plating of the Ni—Fe alloy using the resist layers A _{1 to} A ₃ and B _{1 to} B ₃ as masks, fitting hole forming members 34A and 34B made of Ni—Fe alloy are formed. In this case, the plating base film 30A, in the periphery of the resist layer A ₂ is covered by the resist layer A _1, growth of plating is delayed by the resist covered portion. Size For this reason, as the plating layer constituting the member 34A is formed away from the resist A ₂ as advances above the resist layer A _2, the members 34A, proceeds outward from the inside, as shown in FIG. 15 The fitting hole 34a is formed so as to increase. The same applies to the fitting hole 34b formed in the member 34B.

In the step of FIG. 15, the resist layers A _{1 to} A ₃ and B _{1 to} B ₃ are removed by chemical treatment or the like. As a result, the fitting hole forming members 34A and 34B each having the fitting holes 34a and 34b are provided on one main surface of the substrate 10 through the plating base films 30A and 30B, respectively. Thereafter, the substrate 10 is separated from the fixed substrate 26 as described above with reference to FIG.

  16 (A) and 16 (B) show another example of the fitting hole forming member creation method. In this example, for the sake of simplicity, a method for creating one fitting hole forming member 38A will be described. However, the fitting hole forming member 38B shown in FIG. 26 can be similarly produced. In FIG. 26, the illustration of the plating base film such as 36A is omitted for simplicity.

  In the step of FIG. 16A, a plating base film 36A having a circular hole 36a is formed on one main surface of the substrate 10 by the resist pattern forming process, the sputtering process, and the lift-off process described above with reference to FIGS. The hole 36a is formed in a circular shape so as to have a slightly larger diameter than the desired fitting hole.

Next, the substrate surface in the hole 36a of the resist layer C _1, are respectively formed by photolithography process of the resist layer C ₂ is on the plating foundation film 34A. Resist layer C ₁ is formed in a cylindrical shape having a hole 36a is smaller than the diameter corresponding to the desired fitting hole, the resist layer C ₂ is collected by the resist layer C ₁ spaced from the resist layer C ₁ by a predetermined distance For example, it is formed in an annular shape so as to surround it. Resist layer C ₂ is not limited to a ring shape, or a polygonal frame shape.

Thereafter, the Ni—Fe alloy selective plating process is performed by using the resist layers C ₁ and C ₂ as a mask to form the fitting hole forming member 38A made of the Ni—Fe alloy. In this case, the plating base film 36A is absent around the resist layer C _1, the growth of plating is delayed by this lack portion. Therefore, the plating layer constituting the member 38A is formed away from the resist layer C ₁ as advances above the resist layer C _1, the members 38A, outwardly from the inside, as shown in FIG. 16 (B) The fitting hole 38a is formed so as to increase in size as the process proceeds.

  According to the fitting hole forming member creation method described above with reference to FIGS. 14 to 16, fitting hole forming members such as 34A, 34B, and 38A can be manufactured with submicron-order accuracy and high yield. Further, each fitting hole is formed so as to increase in size as it advances from the inside to the outside, so that fitting with the fitting pin is facilitated.

In the above-described embodiments, the fitting pins 12A and 12B are exemplified as cylindrical ones, but a polygonal column (for example, a quadrangular column, a hexagonal column, etc.) may be formed. In this case, the fitting hole may be a polygonal shape corresponding to the fitting pin. Further, the shape of the substrate 10 is not limited to a square shape, and may be a circular shape, a polygonal shape, or the like. Incidentally, the fitting pin or a fitting hole forming member may be provided on the main surface forming a convex lens L ₂₁ ~L _24.

FIG. 17 shows an example of a combination microlens array according to the present invention. The microlens array LA ₁ is the same as that described above with reference to FIG. 1, and the same parts are denoted by the same reference numerals and detailed description thereof is omitted.

As an example, the microlens array LA ₂ has a plurality of convex lenses L ₄₁ , by transferring a lens pattern by etching in the same manner as described above with reference to FIGS. L ₄₂ , L ₄₃ ... Are formed, and the other main surface of the substrate 40 is a flat surface. On one main surface of the substrate 40, fitting hole forming members 42A and 42B are provided in the same manner as described above with reference to FIGS. In FIG. 17, the illustration of the plating base film under the members 42A and 42B is omitted.

By making one main surface of the substrate 10 face one main surface of the substrate 40 and fitting the fitting pins 12A and 12B into the fitting holes of the members 42A and 42B, the microlens arrays LA ₁ and LA ₂ are formed. Are connected to each other. The lengths of one side of the substrates 10 and 40 are both about 3 mm, the thicknesses of the substrates 10 and 40 are both about 200 μm, and the distance between convex lenses (for example, between L _{11 and} L ₄₁ ) is 50 μm. The thickness T of the combined microlens array can be about 500 μm.

FIG. 18 shows a simulation result of a pair of opposed lenses in the combination microlens array of FIG. The lens La is a biconvex lens composed of convex lenses L ₁₁ and L ₂₁ , and the lens Lb is a plano-convex lens composed of a convex lens L ₄₁ .

The lenses La and Lb are arranged with their optical axes aligned with the straight line ZZ ′, and the distance D between the lenses La and Lb is 50 μm. In the lens La, the thickness T ₁ was 0.2 mm, and the curvature radii of the curved surfaces S ₁ and S ₂ were both 0.6 mm. Further, in the lens Lb, the thickness _{T 2} are, 0.2 mm, the radius of curvature of the curved surface _{S 3} was 0.6 mm. Under such conditions, NA = 0.6 was obtained.

  In the combination microlens array shown in FIG. 17, the fitting pins 12A and 12B may be provided on the substrate 40 side and the fitting hole forming members 42A and 42B may be provided on the substrate 10 side to achieve the fitting. .

  19 to 25 show a method for manufacturing a microlens array according to another embodiment of the present invention. In this microlens array, a fitting hole forming member having a plurality of fitting holes for fitting a plurality of optical fibers is formed on the lens forming surface in the microlens array.

In the process of FIG. 19, convex lenses L _{51 to} L ₅₄ are formed on one main surface of a light transmitting substrate 50 made of a quartz substrate fixed to a fixed substrate 52 in the same manner as described above with reference to FIGS. Resist layers 54 and R _{11 to} R ₁₄ are formed on one main surface 50 by photolithography. The resist layer 54 is formed so as to have a hole 54 a that exposes a lens arrangement region including the convex lenses L _{51 to} L ₅₄ , and the resist layers R _{11 to} R ₁₄ are convex lenses L _{51 to} L in the hole 54 a of the resist layer 54. ₅₄ are formed in a circular shape so as to cover the central portion of each.

In the process of FIG. 20, a metal film 56A made of a Ni—Fe alloy is formed on the substrate 50 by sputtering to cover the resist layers 54 and R _{11 to} R ₁₄ . The metal film 56A adheres to the upper surface of the substrate 50 between the resist layer 54 and the resist layers R _{11 to} R ₁₄ .

In the step of FIG. 21, the resist layers 54, R _{11 to} R ₁₄ and the metal film 56A thereon are removed by lift-off processing. As a result, the portion 56 of the metal film 56A adhering to the upper surface of the substrate 50 remains as a plating base film in a planar pattern as shown by a solid line in FIG. FIG. 21 corresponds to a cross section taken along line YY ′ of FIG. The plating base film 56 has holes K _{1 to} K ₄ corresponding to the resist layers R _{11 to} R ₁₄ , respectively. These holes K _{1 to} K ₄ expose the central portions of the convex lenses L _{51 to} L ₅₄ , respectively.

In the step of FIG. 23, resist layers R _{21 to} R ₂₄ are formed by photolithography so as to cover the exposed portions of the convex lenses L _{51 to} L ₅₄ , respectively. The resist layers R _{21 to} R ₂₄ are formed, for example, in a circular shape corresponding to the optical fiber fitting hole pattern so as to have a size slightly larger than the desired optical fiber fitting hole. The resist layers R _{21 to} R ₂₄ are for imparting outward shapes to the openings of the optical fiber fitting holes. The peripheral portions of the resist layers R _{21 to} R ₂₄ are arranged so as to overlap the plating base film 56 in the peripheral portions of the holes K _{1 to} K ₄ , respectively.

Next, resist layers R _{31 to} R ₃₄ are formed on the resist layers R _{21 to} R ₂₄ , and a resist layer 58 is formed on the upper surface of the substrate 50 by photolithography. The resist layer 58 is formed so as to have a hole 58a corresponding to the hole 54a of the resist layer 54 shown in FIG. 19, and the resist layers R _{31 to} R ₃₄ are respectively formed into desired optical fibers in the hole 58a of the resist layer 58. It formed in a cylindrical shape having a resist layer _R 21 _{to R 24} smaller diameter corresponding to the fitting hole. The resist layer 58 is disposed so as to overlap the plating base film 56 in the peripheral portion of the hole 58a.

Thereafter, the Ni—Fe alloy selective plating process is performed using the resist layers R _{21 to} R ₂₄ , R _{31 to} R ₃₄ , and 58 as a mask to form the fitting hole forming member 60 made of the Ni—Fe alloy. In this case, the plating base film 56 is covered with the resist layers R _{21 to} R ₂₄ around the resist layers R _{31 to} R ₃₄ , respectively, and the growth of plating is delayed in these resist portions. For this reason, the plating layer constituting the member 60 is formed so as to be separated from the resist layer R ₃₁ as it proceeds above the resist layer R ₃₁ , and as shown in FIG. optical fiber fitting hole M ₁ is formed such that the size (diameter) increases. The same applies to the optical fiber fitting holes M _{2 to} M ₄ formed in the member 60.

In the process of FIG. 24, the resist layers R _{21 to} R ₂₄ , R _{31 to} R ₃₄ , 58 are removed by chemical treatment or the like. As a result, the fitting hole forming member 60 having the optical fiber fitting holes M _{1 to} M ₄ is provided on one main surface of the substrate 50 through the plating base film 56. In FIG. 22, the plane pattern of the fitting hole forming member 60 with respect to the plating base film 56 is indicated by a broken line. 24 corresponds to a cross section taken along line YY ′ of FIG.

After the step of FIG. 24, to obtain a micro lens array _{LA 12} separates substrate 50 from the fixed substrate 52 in the step of FIG. 25. In the microlens array LA ₁₂ , convex lenses L _{51 to} L ₅₄ are formed on one main surface of the substrate 50, and a fitting hole forming member 60 is formed via a plating base film 56. Optical fibers F _{1 to} F ₄ can be fitted into the optical fiber fitting holes M _{1 to} M ₄ of the fitting hole forming member 60 as shown in FIG. In such a fitting state, each optical fiber is accurately positioned with respect to the corresponding convex lens. For example, the optical fiber F ₁ is accurately positioned with respect to the convex lens L ₅₁ .

In the example described above with reference to FIGS. 19 to 25, the fitting hole forming member 60 is provided in the plano-convex lens type microlens array LA ₁₂ in which the plurality of convex lenses L _{51 to} L ₅₄ are formed only on one main surface of the substrate 50. in the same manner as described above with reference to FIG 2-8 the plurality of convex lenses _L 51 _{~L 54} on the other main surface of the substrate 50 with the one main surface of the substrate 50 to form a plurality of convex lenses _L 51 _{~L 54} The fitting hole forming member 60 may be provided in a double-sided convex lens type microlens array in which a plurality of convex lenses L _{61 to} L ₆₄ are formed corresponding to each other. The fitting hole forming member corresponding to the fitting hole forming member 60 can be formed by the selective plating process described above with reference to FIG.

  According to the manufacturing method described above with reference to FIGS. 19 to 25, in the microlens array, the fitting hole forming member 60 having a plurality of optical fiber fitting holes can be manufactured with submicron order accuracy. In addition, each optical fiber fitting hole is formed so as to increase in size as it advances from the inside to the outside, so that fitting with the optical fiber is easy.

FIG. 26 shows another example of the combination microlens array according to the present invention. The microlens array LA ₁₁ is almost the same as the microlens array LA ₁ described above with reference to FIGS. 1 to 13, and the same reference numerals are given to the same parts. A difference from the microlens array LA ₁ is that fitting hole forming members 38A and 38B are provided in place of the fitting pins 12A and 12B as described above with reference to FIG. The fitting hole forming members 34A and 34B described above with reference to FIGS. 14 and 15 may be used instead of the fitting hole forming members 38A and 38B.

The microlens array LA ₁₂ is a microlens array similar to that described above with reference to FIGS. 19 to 25, and the convex lens L ₅₁ to the other main surface opposite to the main surface on which the convex lenses L ₅₁ to L ₅₄ are provided. fitting pins 62A so as not to overlap the lens arrangement region including L _54, corresponds to that provided 62B, it has a number of convex lenses arranged similarly to the microlens array LA ₁₁ in a matrix. The fitting pins 62A and 62B can be manufactured in the same manner as the fitting pins 12A and 12B described above with reference to FIGS. In FIG. 26, illustration of the plating base film under the fitting pins 62A and 62B is omitted.

By making the other main surface of the substrate 50 face the one main surface of the substrate 10 and fitting the fitting pins 62A and 62B into the fitting holes of the members 38A and 38B, the microlens arrays LA ₁₁ and LA ₁₂ are formed. Are connected to each other. Before or after such a coupling operation, the optical fibers F _{1 to} F ₄ can be fitted into the optical fiber fitting holes M _{1 to} M ₄ of the fitting hole forming member 60, respectively.

  In the combination microlens array shown in FIG. 26, fitting pins 62A and 62B may be provided on the substrate 10 side and fitting hole forming members 38A and 38B may be provided on the substrate 50 side to achieve fitting. .

1 is a perspective view showing a microlens array according to an embodiment of the present invention. It is sectional drawing which shows the resist layer formation process in the manufacturing method of the micro lens array of FIG. FIG. 3 is a cross-sectional view showing a lens forming process following the process of FIG. 2. It is sectional drawing which shows the resist layer formation process following the process of FIG. It is sectional drawing which shows the metal film formation process following the process of FIG. FIG. 6 is a cross-sectional view showing a lift-off process following the process of FIG. 5. It is sectional drawing which shows the board | substrate peeling and fixing process following the process of FIG. It is sectional drawing which shows the lens formation process following the process of FIG. It is sectional drawing which shows the resist layer formation process and metal film formation process following the process of FIG. FIG. 10 is a cross-sectional view showing a lift-off process following the process of FIG. 9. It is sectional drawing which shows the selective plating process following the process of FIG. FIG. 12 is a cross-sectional view showing a resist removal step subsequent to the step of FIG. 11. It is sectional drawing which shows the isolation | separation process following the process of FIG. It is sectional drawing which shows the resist layer formation process and selective plating process in the fitting hole formation member preparation method. It is sectional drawing which shows the resist removal process following the process of FIG. It is sectional drawing which shows the other example of the fitting hole formation member preparation method. It is sectional drawing which shows an example of the combination microlens array which concerns on this invention. FIG. 18 is an optical path diagram showing a simulation result of a pair of opposed lenses in the combination microlens array of FIG. 17. It is sectional drawing which shows the resist layer formation process in the manufacturing method of the microlens array which concerns on other embodiment of this invention. FIG. 20 is a cross-sectional view showing a metal film forming step that follows the step of FIG. 19. FIG. 21 is a cross-sectional view showing a lift-off process following the process of FIG. 20. FIG. 22 is a plan view showing a planar pattern of a plating base film formed in the step of FIG. 21. FIG. 22 is a cross-sectional view showing a resist layer forming step and a selective plating step following the step of FIG. 21. FIG. 24 is a cross-sectional view showing a resist removing process following the process of FIG. 23. FIG. 25 is a cross-sectional view showing a separation step that follows the step of FIG. 24. It is sectional drawing which shows the other example of the combination microlens array which concerns on this invention. It is sectional drawing which shows the resist layer formation process in the manufacturing method of the conventional microlens array. It is sectional drawing which shows the lens material etching process and resist layer formation process following the process of FIG. FIG. 29 is a cross-sectional view showing a substrate etching step following the step of FIG. 28. It is sectional drawing which shows the state which connected the optical fiber to the micro lens array of FIG.

Explanation of symbols

10, 40, 50: translucent substrate, 12A, 12B, 62A, 62B: fitting pins, 20,26,52: fixed _{substrate, 22,28,32A, 32B, 54,58, S} 1 ~S 4, A _{1 to} A ₃ , B _{1 to} B ₃ , C ₁ , C ₂ , R _{11 to} R ₁₄ , R _{21 to} R ₂₄ , R _{31 to} R ₃₄ : Resist layer, 24A, 30, 56A: Metal film, 24: Position alignment marks, 30A, 30B, 36A, 56 : plating foundation film, 34A, 34B, 38A, 38B , 42A, 42B, 60: fitting hole forming _{member, L 11 ~L 14, L 21} ~L 24, L 41 ~ _{L 44, L 51 ~L 54,} L 61 ~L 64: convex _lens, F 1 _{~F 4:} optical _{fiber, LA 1, LA 2, LA} 11, LA 12: microlens array.

Claims (7)

Preparing a translucent substrate having one and the other main surfaces facing each other;
Transferring a lens pattern to one main surface of the translucent substrate by etching to form a plurality of first convex lenses;
Forming a plurality of second convex lenses by transferring a lens pattern to the other main surface of the translucent substrate so as to face the plurality of first convex lenses, respectively.
A plurality of plating base films so as not to overlap a lens arrangement region including a plurality of convex lenses formed on the one main surface on at least one main surface of the one main surface and the other main surface of the translucent substrate Forming a step;
Forming a plurality of fitting pins on each of the plurality of plating base films by selective plating, respectively. Preparing a translucent substrate having one and the other main surfaces facing each other;
Transferring a lens pattern to one main surface of the translucent substrate by etching to form a plurality of convex lenses;
Forming a plurality of plating base films on one main surface or the other main surface of the translucent substrate so as not to overlap a lens arrangement region including a plurality of convex lenses formed on the one main surface;
Forming a plurality of fitting pins on each of the plurality of plating base films by selective plating, respectively. Preparing a translucent substrate having one and the other main surfaces facing each other;
Transferring a lens pattern to one main surface of the translucent substrate by etching to form a plurality of first convex lenses;
Forming a plurality of second convex lenses by transferring a lens pattern to the other main surface of the translucent substrate so as to face the plurality of first convex lenses, respectively.
A plurality of plating base films so as not to overlap a lens arrangement region including a plurality of convex lenses formed on the one main surface on at least one main surface of the one main surface and the other main surface of the translucent substrate Forming a step;
Forming a plurality of fitting hole forming members each having a fitting hole on the plurality of plating base films by selective plating, respectively. Preparing a translucent substrate having one and the other main surfaces facing each other;
Transferring a lens pattern to one main surface of the translucent substrate by etching to form a plurality of convex lenses;
Forming a plurality of plating base films on one main surface or the other main surface of the translucent substrate so as not to overlap a lens arrangement region including a plurality of convex lenses formed on the one main surface;
Forming a plurality of fitting hole forming members each having a fitting hole on the plurality of plating base films by selective plating, respectively.   5. The selective plating process according to claim 3 or 4, wherein the size of the fitting hole is increased as it advances from the inside to the outside by utilizing a delay in plating growth in the vicinity of the inner wall of each fitting hole. Manufacturing method of micro lens array. Preparing a translucent substrate having one and the other main surfaces facing each other;
Transferring a lens pattern to one main surface of the translucent substrate by etching to form a plurality of convex lenses;
Forming a plating base film on one main surface of the translucent substrate so as to expose at least central portions of the plurality of convex lenses, respectively;
Forming a fitting hole forming member having a plurality of optical fiber fitting holes respectively corresponding to the exposed portions of the plurality of convex lenses on the plating base film by a selective plating process.   In the selective plating process, the size increases as the optical fiber fitting hole is advanced from the inside to the outside by utilizing the delay of plating growth in the vicinity of the inner wall of each optical fiber fitting hole of the fitting hole forming member. The method for producing a microlens array according to claim 6 formed as described above.

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