JP4923555B2 - Manufacturing method of resin film and optical wiring - Google Patents

Description

  The present invention relates to a resin film and an optical wiring using the resin film.

  In order to transfer high-speed and large-capacity data, optical communication is generally performed. Optical communication not only has a wider bandwidth than communication using electrical wiring, but also has the advantage that it is not affected by noise. Because of such advantages, optical communication is required for transmission over a relatively short distance connecting the substrates in the apparatus. In order to transmit a plurality of data in a short distance in parallel like data transmission between substrates, a flexible sheet-like optical waveguide provided with a plurality of circuits has been proposed.

  For example, a method has been proposed in which a laminate in which a core sheet is sandwiched between a pair of clad sheets is used as an optical waveguide sheet by compression molding (see, for example, Patent Document 1). However, in such a method, the core layer and the clad layer are deformed to form a waveguide. However, according to such a method, stress and orientation are generated in the deformed portion and surrounding molecules, so that the refractive index is reduced. There is a problem that anisotropy occurs, propagation of propagation light increases, and high-density information transmission is likely to be difficult. Further, since the core layer is continuous in the direction other than the light traveling direction, light is likely to leak.

  In addition, 1) a clad layer and a core layer are sequentially formed on a Cu-Si substrate, 2) a core to be a waveguide is formed by photolithography and dry etching, 3) a clad layer is covered, and 4) a method of peeling the substrate is performed. A method for obtaining a flexible embedded optical waveguide is also proposed (see Patent Document 2). In this case, the loss of light can be suppressed to some extent compared with the former because it is a buried type, but since vacuum processing, spin coating, photolithography, dry etching, etc. are required, only single wafer processing can be performed and the cost is high. It is difficult to obtain a long or large area. In addition, it is difficult to form a core with a cross-section other than rectangular, and the loss is greater than that of a circular or elliptical core, or the loss is not acceptable due to the roughness of the interface because the core layer is formed by spin coating. Etc. had occurred.

On the other hand, optical fiber is used for medium and long-distance transmission such as transmission between devices. Recently, in home networks and in-vehicle communication, a plurality of optical fibers are bundled to form a sheet, and information communication is performed on other channels. An attempt is being made. For example, an optical wiring sheet having a plurality of optical fibers inserted into a conduit has been proposed (see Patent Document 3). In this method, since the optical fiber can be exchanged even if the terminal processing at the time of connection fails, the yield does not decrease as compared with the conventional optical fiber sheet. However, optical wiring sheets using optical fibers are expensive for each optical fiber, and it is necessary to terminate each fiber separately. Yes.
JP 2001-281484 A (page 2) JP-A-8-304650 (2nd page) JP 2004-205834 A (2nd page)

  The object of the present invention is to solve such problems, to reduce loss, to easily increase the area and length, and to reduce the cost between devices, between devices, between chips in a device, etc. An optical waveguide resin film suitable for long-distance communication is provided. Further, the present invention provides a method for producing a film laminated in multiple layers in the width direction with high accuracy and efficiency.

1) A method for producing a film in which a resin A serving as a clad and a resin B serving as a core are laminated in the film width direction, and at least (a) each of the resin A serving as the clad and the resin B serving as the core passes therethrough. The resin A or the resin B is selectively provided for each slit adjacent to the liquid reservoirs of the resin A and the resin B provided on the upstream side of the plurality of slits. A plurality of laminar resin flows formed by alternately introducing elements A and (b) the resin A serving as the cladding and the resin B serving as the core pass through the numerous slits are layered in a predetermined order. And laminating in a film width direction in a laminating apparatus having an element B provided with a first merging portion for merging and forming a first laminar resin flow, A resin film having a length of 2 m or more comprising a resin A and a core resin B, the resin A serving as a clad and the resin B serving as a core are thermoplastic resins, and in the resin A serving as a clad, The dispersion comprising the resin B serving as a core having a structure satisfying the following formulas (1) and (2), and present in the range of 30 to 300 per 1 cm in the width direction of the film is the width of the film. A method for producing a resin film, wherein the film has a thickness unevenness of 15% or less in a cross section in the direction-thickness direction, which is arranged substantially parallel to the surface of the film at substantially equal intervals.
L ≧ 1m Formula (1)
1 μm ≦ Wc ≦ 10000 μm Formula (2)
L: Length of the dispersion in the film longitudinal direction Wc: Length of the dispersion in the film width direction at the center of the dispersion

The resin film of the present invention, when used as an optical waveguide, is a resin film having a length of 2 m or more comprising at least a resin A serving as a clad and a resin B serving as a core. The dispersion comprising the resin B serving as a core having a structure satisfying (1) and (2), and the dispersion present in the range of 30 to 300 per 1 cm in the width direction of the film is the width direction of the film. Since the resin film is characterized in that the thickness unevenness in the width direction is 15% or less, which is disposed substantially parallel to the film surface at substantially equal intervals in the cross section in the thickness direction, the optical waveguide loss is small. It is easy to increase the area and length, and has an effect such as low cost.
L ≧ 1m formula (1)
1 μm ≦ Wc ≦ 10000 μm Formula (2)
L: Length of the dispersion in the film longitudinal direction Wc: Length of the dispersion in the film width direction at the center of the dispersion Further, if the dispersion further has a structure satisfying the following formula (3), further loss occurs This reduces the optical signal transmission over a longer distance.

Wc ≧ Wa and / or Wc ≧ Wb Equation (3)
Wa: Film width direction length of the dispersion at the position closest to the one film surface side (hereinafter sometimes referred to as “upper bottom”)
Wb: length in the film width direction of the dispersion at a position closest to the other film surface side (hereinafter, sometimes referred to as “lower bottom”)
Further, when the resin A and the resin B are thermoplastic resins, surface processing such as diamond knife processing and thermal compression processing is facilitated, so that connection of light between devices, between boards in a device, and between chips in a board can be performed. Further, it is possible to provide an optical information transmission system that is easier and lower cost.

The method for producing a resin film of the present invention is a method for producing a film in which a resin A serving as a cladding and a resin B serving as a core are laminated in the film width direction, and at least (a) the resin A serving as the cladding. And an element A provided with a large number of slits through which each of the resin B serving as the core passes, and (b) the resin A serving as the cladding and the resin B serving as the core pass through the numerous slits. A large number of laminar resin flows merge in a predetermined order, and are laminated in the film width direction in a laminating apparatus having an element B provided with a first merge portion that forms a first laminar resin flow since the cause is the method for producing the resin film characterized Rukoto, it can be manufactured with high precision and efficiency are stacked in multiple layers in the width direction the film.

To achieve the above object, when used as an optical waveguide, a resin film having a length of 2 m or more comprising at least a resin A serving as a clad and a resin B serving as a core. The dispersion comprising the resin B serving as a core having a structure satisfying (1) and (2), and the dispersion present in the range of 30 to 300 per 1 cm in the width direction of the film is the width direction of the film. It is necessary to be arranged substantially parallel to the film surface at substantially equal intervals in the cross section in the thickness direction L ≧ 1m (1)
1 μm ≦ Wc ≦ 10000 μm Formula (2)
L: Length of the dispersion in the longitudinal direction of the film Wc: Length of the dispersion in the width direction of the film at the center of the dispersion The resin film of the present invention can be made into a buried type waveguide, and thus has a loss. Therefore, it is easy to increase the area and length of the optical waveguide, and it is possible to provide a low-cost optical waveguide. Moreover, since the resin film of the present invention is obtained by a continuous method, there is virtually no restriction on the length, and it can be 1000 m or more.

Here, when used as the optical waveguide of the present invention , as the resin A serving as the cladding and the resin B serving as the core, a thermoplastic resin is preferably used from the viewpoint of ease of production into a resin film and cost.

Preferred resins in the present invention include polymethyl methacrylate (refractive index n is 1.49, hereinafter, refractive index is n), a copolymer containing methyl methacrylate as a main component (n = 1.47 to 1.50), polystyrene ( n = 1.58) and copolymers based on styrene (n = 1.50 to 1.58), cycloaliphatic olefins (n = 1.51 to 1.53), styrene acrylonitrile copolymers (n = 1. 56), poly-4-methylpentene 1 (n = 1.46), ethylene / vinyl acetate copolymer (n = 1,46 to 1.50), polycarbonate (n = 1.50 to 1.57), polyethylene terephthalate ( n = 1.58 to 1.68), polyethylene terephthalate copolymer (n = 1.54 to 1.64), polyethylene naphthalate (n = 1.65 to 1) 73), polychlorostyrene (n = 1.61), polyvinylidene chloride (n = 1.63), polyvinyl acetate (n = 1.47), methyl methacrylate / styrene, vinyltoluene or α-methylstyrene / Maleic anhydride terpolymer or quaternary copolymer (n = 1.50 to 1.58), polydimethylsiloxane (n = 1.40), polyacetal (n = 1.48), polyimide (n = 1.56) To 1.60), fluorinated polyimide (n = 1.51 to 1.57), polytetrafluoroethylene (n = 1.35), polyvinylidene fluoride (n = 1.42), polytrifluoroethylene (n = 1.40), perfluoropropylene (n = 1.34), and binary or ternary copolymers of these fluorinated ethylenes (n = 1.35 to 1.40), poly Kka vinylidene polymethylmethacrylate blend polymer _{(n = 1.42~1.46), CF 2} = CF-O- (CF 2) x-CF = CF 2 monomers of the polymer (n = 1.34) and fluorinated copolymers of ethylene _{(n = 1.31~1.34), CF 2} = CF-O- (CF 2) -0-CF = CF 2 monomers of the polymer (n = 1.31) and fluoride A copolymer of ethylene (n = 1.31 to 1.34), a copolymer mainly composed of fluorinated methacrylate represented by the general formula CH ₂ ═C (CH ₃ ) COORf, wherein the group Rf is (CH ₂ ) n (CF ₂₎ copolymer (n = 1.37-1.42 is _n H), Rf is _{(CH 2)} m _{(CF 2)} those _{n F (n = 1.37~1.40),} Rf is CH · (CF ₃ ) ₂ (n = 1.38) , Rf is C (CF ₃ ) ₃ (n = 1.36), Rf is CH ₂ CF ₂ CHFCF ₃ (n = 1.40), Rf is CH ₂ CF (CF ₃ ) ₂ ( n = 1.37), and copolymers of these fluorinated methacrylates (n = 1.36-1.40), and their fluorinated methacrylate and methyl methacrylate copolymers (n = 1.37-1.43), in general A polymer based on a fluorinated acrylate represented by the formula CH2 = CH · COOR′f, wherein Rf ′ is (CH ₂ ) _m (CF ₂ ) _n F (n = 1.37 to 1.40), Rf ′ is (CH ₂ ) _m (CF ₂ ) _n H (n = 1.37 to 1.41), Rf ′ is CH ₂ CF ₂ CHF · CF ₃ (n = 1.41), Rf Is CH (CH ₃ ) ₂ (n = 1.38) ), And these fluorinated acrylate copolymers (n = 1.36 to 1.41), and these fluorinated acrylates and the aforementioned fluorinated methacrylate copolymers (n = 1.36 to 1.41), and these fluorinated acrylates and fluorine Methacrylate and methyl methacrylate copolymer (n = 1.37 to 1.43), a polymer based on 2-fluoroacrylate represented by the general formula CH ₂ ═CF · COOR ″ f, and a copolymer thereof (n = 1) .37 to 1.42) (where R ″ f is CH ₃ , (CH ₂ ) _m (CF ₂ ) _n F, (CH ₂ ) _m (CF ₂ ) _n H, CH ₂ CF ₂ CHFCF ₃ , C (CF ₃ ) ₃ ).

  Among these, polycarbonate, polymethyl methacrylate, alicyclic olefin, polyimide resin, and amorphous fluorinated polymer are particularly preferable from the viewpoint of strength, heat resistance, transparency, and low loss. Moreover, in order to reduce loss, it is more preferable that hydrogen is deuterated.

  Further, these resins may be homo resins, copolymerized or a blend of two or more. Various additives such as antioxidants, antistatic agents, crystal nucleating agents, inorganic particles, organic particles, thinning agents, thermal stabilizers, lubricants, infrared absorbers, ultraviolet absorbers, for refractive index adjustment A dopant or the like may be added.

  Next, an example of the resin film of the present invention is shown in FIG. FIG. 1 shows a preferred embodiment of the resin film of the present invention as a three-dimensional projection diagram. In FIG. 1, 1 represents resin A, and 2 represents resin B.

In the present invention, as shown in FIG. 1, at least a dispersion made of resin B serving as a core must be included in resin A serving as a cladding. Further, it must contain at least a dispersion in which the length L of the dispersion in the film longitudinal direction is 1 m or more. Here, in FIG. 1, L corresponds to the length of the resin B in the Y direction . As can be understood from achieving means of the present invention to be discussed later, it is also possible to have truly continuous without the length in the longitudinal direction of the essentially dispersion interruption, adjusting the length of the resin film itself By doing so, the length of the dispersion can be adjusted. Thus, in the dispersion of the present invention, the resin A surrounds the resin B in the XZ cross section, but it does not necessarily have to be surrounded in the XY cross section. When L is 30 mm or more, it can be used as a communication means in a flexible apparatus. Moreover, when L is 1 m or more, it is flexible and can be used as a medium / long-distance communication means.

  Moreover, in the resin film of this invention, Wc must be 1 micrometer or more and 10,000 micrometers or less. Hereinafter, a description will be given with reference to FIG.

  FIG. 2 is a plan view illustrating a cross-sectional example in the width direction-thickness direction of the resin film according to a preferred embodiment of the present invention. The X direction corresponds to the width direction, and the Z direction corresponds to the thickness direction. Wc is the length in the width direction in the direction parallel to the film surface passing through the center of the dispersion in the XZ section as already described. Preferably, Wc is 2 μm or more and 2000 μm or less. More preferably, Wc is 3 μm or more and 150 μm or less. If Wc is smaller than 1 μm, it is difficult to make light incident on the dispersion. On the other hand, if it is larger than 10000 μm, the resin sheet thickness is too thick and not flexible, and the loss of light becomes too large. Moreover, it is more preferable that the thickness is 2 μm or more and 2000 μm or less because light from an optical fiber or a surface emitting laser can be easily incident, loss is small, and flexibility is sufficient. Further, when the thickness is 3 μm or more and 150 μm or less, the number of modes is limited because the waveguide diameter is sufficiently small, and therefore, it becomes easier to cope with wide-band communication that is important for transmission at medium and long distances.

The resin film of the present invention, the width direction of the dispersion film - must be arranged substantially parallel to the surface of the substantially equal intervals in the off Irumu the thickness direction in the cross section. Here, the state that “the dispersion is disposed substantially parallel to the surface” refers to a state in which the line connecting the center of the dispersion and the film surface are substantially parallel. FIG. 1 shows a state in which four dispersions are arranged substantially parallel to the surface and are present at substantially equal intervals. In such a case, multi-channel communication is possible and positioning at the time of connection is facilitated.

  Moreover, in the resin film of this invention, it is preferable that the shape of a dispersion satisfy | fills following formula (3).

Wc ≧ Wa and / or Wc ≧ Wb Equation (3)
Here, Wa is the film width direction length of the dispersion at the position closest to the one film surface side, and Wb is the film width direction length of the dispersion at the position closest to the other film surface side. For the sake of convenience, hereinafter, Wa is referred to as an upper base and Wb is referred to as a lower base. A specific example is illustrated in FIG. In such a case, since the reflection loss inside the dispersion is reduced, the loss is reduced. More preferably, Wc is at least 1.05 times the length of Wa and Wb. More preferably, Wa and Wb are almost points, and the shape of the dispersion is a circle or an ellipse. As Wc increases compared to Wa and Wb, the loss decreases, which is preferable.

The width direction - is arranged substantially parallel to the surface in a thickness direction cross-section dispersion, since the presence 300 or less 30 or more in length per 1cm width direction of the film, that Do can communicate with mass . In There Ppo, 3 if 00 pieces larger than, or is difficult to connect too diameter of the portion to be the core is small, preferable for noise or cause by light leakage for the thickness of the cladding is too thin Absent. Further, it is more preferable that the number is 30 or more and 100 or less per 1 cm of width because the wiring efficiency is high and data transmission with a larger capacity is possible.

  Further, in the resin film of the present invention, it is preferable that two or more dispersion groups arranged substantially parallel to the film surface in the cross section in the width direction can increase the number of channels with a smaller area. Here, the dispersion group refers to a set of three or more dispersions arranged at substantially equal intervals in the cross section in the width direction-thickness direction of the film and substantially parallel to the film surface. As a specific example, the case where there are two or more dispersion groups arranged substantially parallel to the film surface is illustrated in FIGS. 3 and 4. FIG. 3 is a plan view of a cross section in the width direction-thickness direction of a resin film in which the cross-sectional shape of the dispersion is substantially square and there are two dispersion groups arranged substantially parallel to the film surface. FIG. 4 is a plan view of a cross section in the width direction-thickness direction of a resin film in which the cross-sectional shape of the dispersion is substantially round and there are two dispersion groups arranged substantially parallel to the film surface. In the etching method or the like, when stacking cores in order to increase the number of channels, the number of processes is extremely increased, resulting in high cost, which is not practical. Therefore, since it can be performed in one process, it can be manufactured at a very low cost with high accuracy.

  The resin film of the present invention preferably has a layer composed of a resin A having a thickness of 10 μm or more and 500 μm or less on one or both sides. Here, the layer made of the resin A having a thickness of 10 μm or more and 500 μm or less means a layer made of the resin A not containing a dispersion having a thickness of 10 μm or more and 500 μm or less. Further, this layer is not necessarily the outermost surface, and a layer made of another resin may be formed on the outermost layer. If there is a layer made of resin A of 10 μm or more and 500 μm or less on one side or both sides, even if the surface is scratched, there is almost no effect on the resin B serving as the core, so there is little loss of loss due to surface scratches, etc. Therefore, it is preferable. More preferably, they are 15 micrometers or more and 100 micrometers or less. When the thickness is 15 μm or more and 100 μm or less, flexibility and handling properties are improved, and it is also possible to mount a light receiving element such as a surface emitting laser or a photodetector, an electronic component, or the like on the surface.

  The bending strength is preferably 5 N / mm or more and 150 N / mm or less. More preferably, it is 15 N / mm or more and 80 N / mm or less. If it is 5 N / mm or less, the self-supporting property is insufficient, so that the handling property may be poor or the buckling may occur during use, and if it is larger than 150 N / mm, the flexibility is impaired. It is not preferable. On the other hand, when it is 15 N / mm or more and 80 N / mm or more, an optical wiring sheet that is optimal in handling and flexibility is obtained.

In the present invention, the difference (nb−na) between the refractive index na of the resin A serving as the cladding and the refractive index nb of the resin B serving as the core is preferably 0.001 or more. More preferably, it is 0.010 or more. More preferably, it is 0.030 or more. When it is 0.001 or more, it is suitable as an optical wiring. Moreover, since it is easy to adjust the incident axis of light when it is 0.010 or more, it is preferable. Furthermore, if it is 0.030 or more, there is almost no false signal due to light leakage between channels, which is more preferable. As a preferable resin combination in which the difference (nb−na) between the refractive index na of the resin A serving as the clad and the refractive index nb of the resin B serving as the core is 0.001 or more, any of the above-described resins can be used. You can choose a combination. More preferably,
Resin A: Fluoropolymer described above, Resin B: Polymethyl methacrylate or copolymer thereof Resin A: Polymethyl methacrylate, Resin B; Copolymer resin A: Polymethyl methacrylate, resin B: Alicyclic Polyolefin resin A: alicyclic polyolefin, resin B: alicyclic polyolefin resin A: polyethylene terephthalate copolymer, resin B: polyethylene terephthalate resin A: polyethylene terephthalate, resin B: polyethylene naphthalate or polyethylene naphthalate copolymer resin A: polycarbonate , Resin B: polycarbonate resin A: polycarbonate, resin B: a combination of polyethylene terephthalate or polyethylene terephthalate copolymer, etc. In combination, excellent heat resistance and moisture resistance, and since the excellent productivity, it is possible to provide an inexpensive optical waveguide.

  The resin film of the present invention is suitable as an optical waveguide when the resin A is a clad and the resin B is a core. In addition, as a protective layer on the outer periphery of the clad, other resins such as polyamide, polyester elastomer, polyamide elastomer, polystyrene elastomer, polyolefin elastomer, poly-4-methylpentene 1, polyvinylidene fluoride, ionomer, ethylene / ethyl acrylate copolymer, An ethylene / vinyl acetate copolymer, a vinylidene fluoride copolymer, polymethyl methacrylate, polystyrene, ABS, polybutylene terephthalate, polyethylene, vinyl chloride and the like may be coated. In addition, by mixing carbon black, lead oxide, titanium oxide, or organic pigment into the protective layer resin and coloring the protective layer, leakage of the transmitted light inside the resin film is prevented, and the external light inside the resin film The light shielding effect which prevents the penetration | invasion into can be improved. Further, in order to prevent deterioration of the protective layer resin and the resin that becomes the core and cladding, an ultraviolet absorber, HALS, and the like may be added.

  Since the resin film of the present invention can be produced by a continuous method, it can be wound into a roll shape, and can also be processed with a roll-to-roll when forming an optical waveguide. Moreover, since it is a flat film shape, even if it rolls up, it is not bulky compared with what bundled the optical fiber in tape shape, etc., and its productivity is also high.

  By using the resin film of the present invention or a part of the resin film and connecting to a laser, a surface emitting laser, a photodiode, a photodetector, an optical fiber or the like, an optical wiring can be obtained. It is also possible to form electrical wiring on the optical waveguide resin film, photoelectrically convert the optical waveguide resin film, convert the transmitted optical signal to an electrical signal, and then connect to the equipment. It is also possible to carry out electricity. Even if a part of the resin film of the present invention is cut or punched out to form an optical waveguide, it can be produced at a lower cost than the etching method or the like.

The method for producing a resin film of the present invention is a method for producing a film in which a resin A serving as a cladding and a resin B serving as a core are laminated in the film width direction, and at least (a) the resin A serving as the cladding and An element A provided with a large number of slits through which each of the resin B serving as the core passes, and (b) a large number formed by the resin A serving as the cladding and the resin B serving as the core passing through the numerous slits. Are laminated in the film width direction in a laminating apparatus having the element B provided with the first joining portion that forms the first layered resin stream. There must be. In such a manufacturing method, a laminated film that is substantially continuous in the longitudinal direction and laminated in the very wide width direction can be easily obtained. Moreover, the lamination accuracy in the width direction is high, and the thickness of the resin A layer (the thickness of the resin A layer in the film width direction) can be made very thin. Specifically, it can be thinned to about 0.1 μm. For this reason, when an optical wiring is used, an optical wiring having a small core diameter can be easily obtained.

  Moreover, as a manufacturing method of the resin film of the present invention, the laminating apparatus includes (c) two or more of the elements A independently, and two or more of the elements B independently. (D) having an element C provided with a liquid reservoir for receiving each resin stream supplied to the resin flow laminating apparatus and supplying each resin stream to each element A; e) The first layered resin flow formed in each of the elements B merges in a predetermined order in a layered manner, and an element D provided with a second joining portion that forms a second layered resin flow is provided. It is preferable to laminate using the laminating apparatus which has. In such a manufacturing method, the structure as shown in FIG. 3 or FIG. 4 can be formed with high accuracy and efficiency. Therefore, when the optical wiring is used, the core is three-dimensionally arranged and the core position accuracy is very high, so that large capacity communication is possible and the connection cost can be reduced. Also, the two first layered resin streams are not stacked in the film thickness direction as shown in FIG. 3 or FIG. It is also possible for the flow to have a continuous layer structure. In this case, the number of layers can be further increased in the width direction.

  In the method for producing a resin film of the present invention, it is preferable that the outermost layer serving as both end portions of the film be 5 times or more thicker than the thickness of most other layers. For example, as shown in FIG. 10 (e), when both ends of the film (both ends in the X direction) are thicker, the lamination accuracy is further improved. In particular, when the outermost layer at both ends of the film is 5 times thicker than the thickness of most other layers, the part that becomes the product can be collected most efficiently, so the intercourse rate decreases and the loss is suppressed. be able to.

  In the method for producing a resin film of the present invention, at least one surface in a direction substantially perpendicular to the laminating direction of the first layered resin flow or the second layered resin flow may be coated with the resin A, the resin B, or the resin C. preferable. More preferably, both surfaces of the first layered resin flow or the second layered resin flow in the direction substantially perpendicular to the laminating direction are coated with the resin A, the resin B, or the resin C. Here, the resin C is a resin different from the resin A and the resin B, or a resin in which the resin A and the resin B are mixed. If it does in this way, the thickness nonuniformity of a film width direction will reduce. Further, since the smoothness of the surface is also improved, various surface treatments such as printing, bonding, vapor deposition, sputtering and plating are possible.

  Next, the preferable manufacturing method of the resin film of this invention is demonstrated below.

  Two types of resins A and B are prepared in the form of pellets. The pellets are supplied to the extruder after pre-drying in hot air or under vacuum as necessary. In the extruder, the heat-melted resin is made uniform in the amount of resin extruded by a gear pump or the like, and foreign matter or denatured resin is removed through a filter or the like.

  Resins sent from different flow paths using these two or more extruders are then sent to the composite device. An example of a preferred composite device of the present invention is shown in FIG. FIG. 5 illustrates a plan view of a composite device including the core array portion 4 and the clad coating portion 5 and cross-sectional shapes at each flow path position in the composite device. In the core arrangement portion, first, the resin A (1 in FIG. 5) and the resin B (2 in FIG. 5) as the cladding are alternately arranged (LL ′ cross section in FIG. 5 (b)), and then necessary. According to the shape of the core to be compressed once in the width direction (MM ′ cross section FIG. 5C). When compressing in the width direction, it may be simultaneously compressed or widened in the thickness direction as necessary. Next, the resin A is formed so that the fluid (FIG. 5 (d) 6) in which the resin A and the resin B are alternately arranged is used as a core and the resin A becomes a sheath (FIG. 5 (d) 7) in the clad coating portion. Are supplied (NN ′ cross section, FIG. 5 (d)), and then they are joined (OO ′ cross section, FIG. 5 (e)). Accordingly, the resin A includes a dispersion made of the resin B having a structure satisfying the formulas (1) to (2), and the dispersion is present in three or more in the width direction-thickness direction cross section, and Can be obtained as a continuous body efficiently.

  Next, the core arrangement part in the composite apparatus will be described in detail with reference to FIG. FIG. 6 is a plan view of the core array portion in the composite apparatus. The core arrangement part 4 includes a side plate 8, a resin A supply part 9, a slit part 10, a resin B supply part 11, and a side plate 12, which are used by being integrated. The core array part 4 of FIG. 6 has two inlets 13 derived from the resin A supply part 9 and the resin B supply part 11. Here, the types of resin introduced into the plurality of slits existing in the slit portion are the bottom surfaces of the liquid reservoir portions 14 of the resin A supply portion 9 and the resin B supply portion 11 and the end portions of the slits in the slit members. And is determined by the positional relationship. The mechanism will be described below.

  FIG. 7A is an enlarged view of the slit portion 10. A p-p ′ cross section showing the shape of the slit 16 a is (b) in the figure, and a q-q ′ cross section showing the shape of the slit 16 b is (c) in the figure. As shown in (b) and (c), the ridge line 19 of each slit has an inclination with respect to the thickness direction of the slit member.

  In FIG. 8, the resin A supply part 9, the slit part 10, and the resin B supply part 11 are shown among the core arrangement parts. And the height of the bottom face 20 of the liquid reservoir in each of the resin A supply part 9 and the resin B supply part 11 is located between the upper end part 18 and the lower end part 17 of the ridge line 19 existing in the slit part. . Accordingly, the resin is introduced from the liquid reservoir 14 from the side where the ridgeline 19 is high (arrow 21 in FIG. 8), but the slit is sealed from the side where the ridgeline 19 is low and the resin is introduced. Not.

  Although not shown, in the slit adjacent to the slit noted in FIG. 8, the ridge line of the slit is arranged at an angle opposite to that in FIG. 8, and is introduced from the resin B supply unit 11 into the slit unit 10. Thus, since the resin A or B is selectively introduced for each slit, a resin flow having a structure in which the core and the clad are arranged is formed in the slit portion 10 and flows out from the outlet 15 below the member 10. To do. That is, the slit of the slit portion 10 corresponds to the element A that is a feature of the present invention, the lower portion of the slit portion 10 corresponds to the element B, and the resin supply portions 9 and 11 correspond to the element C.

  Because of this structure, the number of cores can be easily adjusted by the number of slits. The length in the width direction of the core dispersion can be easily adjusted by the slit shape (length, gap), fluid flow rate, degree of compression in the width direction, and clad coating amount. On the other hand, the shape of the core is basically rectangular, but by adjusting the viscosity difference between the resin A and the resin B, the rectangular shape is deformed in the flow process and becomes an ellipse or a circle. It is possible to A preferable number of slits is 5 or more and 3000 or less in one slit portion. When the number is less than 5, the number of cores is too small, and the efficiency is poor. On the other hand, when the number is more than 3000, it becomes difficult to control the flow rate unevenness and the accuracy of the core diameter is insufficient, so that it becomes difficult to connect light. More preferably, it is 50 or more and 1000 or less. In this range, it is possible to provide a highly efficient multi-channel optical wiring while controlling the core diameter with high accuracy. In addition, when it has 200 or more cores, it is preferable to use the core arrangement | sequence part which has the 2 or more slit part separately mentioned later. This is because if there are 400 or more (200 or more cores) slits in one slit part, it is difficult to make the flow rate of each slit uniform.

  Further, the fluid having the arrangement structure of the resin A and the resin B thus obtained is further combined at the clad coating portion so that the resin A is coated on the outer periphery thereof, whereby the structure having the aspect of the present invention is obtained. Form.

  Further, when two or more dispersion groups arranged in parallel to the surface as illustrated in FIGS. 3 and 4 are formed, it is preferable to use a core array portion as illustrated in FIG. Here, FIG. 9A is a plan view of the apparatus 10 that alternately arranges the separately supplied resin A and resin B, and includes a side plate 22, a resin A supply unit 23, a slit unit 24, and a resin B supply unit. 25, a slit portion 26, a resin A supply portion 27, and a side plate 28. The core array part 4 of FIG. 9 has three inlets 13 derived from the resin A supply part 23, the resin B supply part 5, and the resin A supply part 27.

  Here, the types of resin introduced into the plurality of slits existing in the slit part are the bottom surfaces of the liquid reservoirs 14 of the resin A supply parts 23 and 27 and the resin B supply part 25 and the slits of the slit members. Since it is determined in the same manner as in the above method depending on the positional relationship with the end portion, the outlet 15 becomes a fluid having a structure in which a two-stage core and cladding are arranged as shown in FIG. By covering this with the clad coating portion, it is possible to obtain a fluid having the structure of FIG. That is, in this case, the cladding covering portion corresponds to the element D.

  Further, as shown in FIG. 9, it is possible to obtain a resin film having a wider width and a more efficient number of cores by using a core array portion having two or more slit portions separately. That is, in FIG. 9, the position of the outlet that exists in the separate slit portion exists at the same position on the X coordinate axis, but is shifted so that the separate outlet does not overlap, and in the flow path from the outlet to the cladding coating By moving in the Z-axis direction and overlapping on the Z-coordinate axis, a resin film having a large number of cores arranged in parallel on the film surface can be obtained. When a wide resin film is obtained, a plurality of optical wiring films can be manufactured from a single resin film, and the yield is further improved.

  In addition, in order to obtain a structure in which the cross-sectional shape of the dispersion which is a more preferable embodiment of the present invention satisfies Wc ≧ Wa and / or Wc ≧ Wb, the melt viscosity of the resin B should be equal to or higher than the melt viscosity of the resin A. preferable. Further, in order to satisfy Wc ≧ 1.05 × Wa and / or Wc ≧ 1.05 × Wb, it is preferable that the melt viscosity of the resin B is 1.2 times or more the melt viscosity of the resin A. Moreover, in order for the cross-sectional shape of the dispersion to be a circle or an ellipse, the melt viscosity of the resin B is preferably 1.5 times or more the melt viscosity of the resin A.

  The fluid arranged by the dispersion thus obtained is arranged in a sheet shape so as to have a required width with a die, and then discharged, extruded onto a cooling body such as a casting drum, and cooled and solidified. The When discharging from the die, the spacing between the dispersions may fluctuate due to a neck-down phenomenon, so it is preferable to provide an edge guide at the end of the die lip. The edge guide is provided between the die lip and the cooling body in order to constrain the end of the resin film discharged from the die. Down can be suppressed. By doing so, the resin film discharged from the die is thinned in the thickness direction depending on the relationship between the discharge amount and the take-off speed, but the width direction dimension does not change, so the width direction accuracy of the dispersion is improved. .

  In addition, as a cooling method, using a wire-like, tape-like, needle-like or knife-like electrode, it is brought into close contact with a cooling body such as a casting drum by electrostatic force and rapidly cooled and solidified, or a slit-like, spot-like, surface It is preferable to use a method in which air is blown out from a sheet-shaped device and brought into close contact with a cooling body such as a casting drum and rapidly cooled and solidified, or a method in which the nip roll is brought into close contact with the cooling body and rapidly cooled and solidified.

  In the resin film of the present invention, the thickness unevenness in the width direction is preferably 15% or less. If the thickness unevenness in the width direction is larger than 15%, it becomes difficult to mount various electronic components and surface emitting lasers on the film surface, and the accuracy of the interval between the core dispersions is significantly reduced. The viscosity ratio (melt viscosity of resin A / melt viscosity of resin B) is 0.4 to 3 in order to reduce the thickness unevenness in the width direction, which is because light incident connection is not easy, to 15% or less. Is preferred. Moreover, it is also preferable to use an edge guide or to make it adhere to a cooling body with a nip roll.

An evaluation method of physical property values used in the present invention will be described.
(Method for evaluating physical properties)
(1) Internal shape The internal shape of the film was observed with an electron microscope or an optical microscope for a sample obtained by cutting a cross section (width direction-thickness direction cross section and longitudinal direction-thickness direction cross section) using a microtome. When the diameter of the dispersion is small, a transmission electron microscope HU-12 type (manufactured by Hitachi, Ltd.) is used, the cross section of the film is magnified 3000 to 40000 times, and a cross-sectional photograph is taken. The shape and layer thickness were measured. The embodiment of the present invention was not carried out because sufficient contrast was obtained, but the contrast may be increased by using a known dyeing technique depending on the combination of resins used. In addition, when the diameter of the dispersion is large,
(2) Refractive index The refractive index of resin was measured in accordance with JIS K7142 (1996) A method. In addition, the refractive index of resin in this invention was measured about each resin simple substance which comprises a resin film.

(3) Loss It was performed in an environment of 25 ° C. and 65% RH according to JIS C6823 (1999) cutback method (IEC 60793-C1A). An LED having a wavelength of 850 nm was used as the light source.

(4) Unevenness in thickness The film was sampled to have a width (longitudinal direction) of 30 mm width and a length (width direction) of 30 mm to 1 m. For the measurement, the thickness of the film is continuously measured using a film thickness tester “KG601A” and an electronic micrometer “K306C” manufactured by Anritsu Corporation. The conveyance speed of the film was 1.5 m / min. R (= Tmax−Tmin) is determined from the maximum thickness Tmax (μm) and minimum value Tmin (μm) at the measurement length, and thickness unevenness (%) = R / Tave from R and the average thickness Tave (μm) of 1 m length. It calculated | required as x100. The thickness unevenness was an average value of 10 measurements.

Example 1
Resin A and Resin B were prepared as two types of resins. As resin A, 1,1,2,2-tetrahydroperfluorodecyl methacrylate / 2,2,3,3-tetrafluoropropyl methacrylate / 2,2,2-trifluoroethyl methacrylate / methacrylic acid copolymer (composition ratio) 40/30/20/10 wt% MFR 55 g / 10 min) was used. Further, as the resin B, polymethyl methacrylate (MFR 50 g / 10 min) was prepared. Each was melted at 260 ° C. with an extruder, passed through a gear pump and a filter, and then supplied to a composite device (number of slits 301 of the slit member 10) as shown in FIG. In the composite apparatus, after the resin A and the resin B are supplied to the slit so that the resin A and the resin B are alternately and the both ends are the resin B in the core arrangement portion, the width is 50 mm at the outlet 15. Compressed in the width direction. The flow rate ratio (A / B) between the resin A and the resin B supplied to the core array portion is 5.7, and the gap between the slits is that the flow rate ratio (A / B) is 5.7. It was designed so that the pressure loss in the slit was constant. Subsequently, after covering the entire surface of the composite resin flow formed in the core array portion with the clad coating portion and the resin A so that the width length of the composite resin flow is not deformed, a die having a die lip width of 100 mm is coated. Supplied to. The molten resin discharged from the die was extruded onto the casting drum while being constrained at the edge by the edge guide, and rapidly cooled and solidified (width 94 mm). Further, the obtained resin film was trimmed with a winder and then wound around a paper tube roll every 1000 m and wound up. The finally obtained film had a thickness of 90 μm and a film width of 70 mm. In addition, 150 dispersions made of the resin B were present in the film width center part 50 mm in the cross section in the width direction-thickness direction, and were arranged in parallel to the film surface at equal intervals. The obtained results are shown in Table 1.

( Comparative Example 5 )
The number of slits in the slit part in the core array part of the composite device is 71, the flow ratio (A / B) between the resin A and the resin B supplied to the core array part is 27, and the gap between the slits is the flow ratio (A / B). ) Was 27, a film was formed under the same apparatus and conditions as in Example 1 except that the pressure loss in the slit was designed to be constant. The thickness of the obtained film was 90 μm, and the width of the film was 70 mm. Further, 35 dispersions made of the resin B were present in the width-direction-thickness cross section in a film width center portion of 50 mm, and were arranged in parallel to the film surface at regular intervals. The obtained results are shown in Table 1.

( Comparative Example 6 )
The flow ratio (A / B) between the resin A and the resin B supplied to the core array portion is 4.7, and the slit gap has a pressure loss in the slit when the flow ratio (A / B) is 4.7. A film was formed under the same apparatus and conditions as in Comparative Example 5 , except that the design was constant. The thickness of the obtained film was 290 μm, and the width of the film was 70 mm. Further, 35 dispersions made of the resin B were present in the width-direction-thickness cross section in a film width center portion of 50 mm, and were arranged in parallel to the film surface at regular intervals. The obtained results are shown in Table 1.

(Example 2 )
A film was formed under the same apparatus and conditions as in Example 1 except that the composite apparatus was the apparatus shown in FIG. 10 (the number of slits 301 in each slit portion 24 and 26 in FIG. 9). The thickness of the obtained film was 160 μm, and the width of the film was 70 mm. In addition, 300 dispersions made of the resin B exist in the film width center part 50 mm in the cross section in the width direction-thickness direction, and two groups of 150 dispersions arranged in parallel to the film surface at equal intervals exist. Was. The obtained results are shown in Table 1.

(Example 3 )
The same apparatus as in Example 2 except that the position of the outlet in the core array part is shifted in the X direction so as not to overlap each other, and supplied to a die having a die lip width of 160 mm to obtain a rapidly solidified sheet. Film formation was performed under conditions. However, after winding with a winder, the resulting resin sheet was further divided into two with a slitter. Finally, two film rolls with a film thickness of 90 μm, a film width of 70 mm, and a winding length of 1000 m were simultaneously obtained. I was able to. In the obtained film, 150 dispersions made of the resin B in the cross section in the width direction-thickness direction were present in a film width central portion of 50 mm, and were arranged in parallel to the film surface at regular intervals. The obtained results are shown in Table 1.

(Example 4 )
A film was formed under the same apparatus and conditions as in Example 1 except that polymethyl methacrylate (MFR 25 g / 10 min) was used as resin B. The thickness of the obtained film was 90 μm, and the width of the film was 70 mm. In addition, 150 dispersions made of the resin B were present in the film width center part 50 mm in the cross section in the width direction-thickness direction, and were arranged in parallel to the film surface at equal intervals. The obtained results are shown in Table 1.

(Comparative Example 1)
A film was formed under the same apparatus and conditions as in Example 1 except that an apparatus consisting only of the core array portion as shown in FIG. 6 was used as the composite apparatus. The thickness of the obtained film was 90 μm, and the width of the film was 70 mm. Moreover, the dispersion did not exist in the cross section in the width direction-thickness direction, and the resin A and the resin B were alternately arranged. The obtained film was lossy due to scratches on the film surface. The obtained results are shown in Table 2.

(Comparative Example 2)
The slit member 10 has 11 slits, is led to the outlet 15 having a width of 150 mm without being widened and compressed, and the flow rate ratio (A / B) between the resin A and the resin B supplied to the core array portion is 1. The gap is designed so that when the flow rate ratio (A / B) is 1, the pressure loss in each slit is constant, and is supplied to a die having a die lip width of 200 mm.・ Film was formed under conditions. The obtained film had a thickness of 10100 μm, and since the film thickness was too thick, the flexibility was lost, making it difficult to wind, and a flat film having a length of 2 m or more could not be obtained. Also, since the film thickness was too thick, it could not be rapidly cooled and solidified, resulting in large thickness unevenness and physical property unevenness in the polymer, resulting in a large loss. Further, five dispersions made of the resin B were present in the width-width-thickness cross section in the film width central portion of 150 mm, and were arranged in parallel and at equal intervals on the film surface. The obtained results are shown in Table 2.

(Comparative Example 3)
A film was formed under the same apparatus and conditions as in Example 1 except that six stages of a two-channel square mixer were introduced between the composite apparatus and the die. The thickness of the obtained film was 41 μm, and the width of the film was 70 mm. In this example, the flow of the resin A and the resin B is disturbed, the shape of the dispersion cannot be controlled, and the average Wc of the dispersion is about 0.7 μm, but a random alloy with L of 10 mm or less. Therefore, it was difficult to make light incident, and there was no effective waveguide distance, and light did not even conduct. The obtained results are shown in Table 2.

(Comparative Example 4)
A film was formed under the same apparatus and conditions as in Example 1 except that the edge guide was not used. The thickness of the obtained film was 90 μm, and the width of the film was 50 mm. In addition, 150 dispersions made of the resin B were present in the film width center portion 50 mm in the cross section in the width direction-thickness direction. However, since the edge guide was not used, a neck-down occurred when the film was taken out from the die, and the width of the film was greatly reduced. For this reason, the dispersion of the shape of the dispersion becomes large, the intervals between the dispersions become uneven, and the loss increases or noise easily occurs due to light leakage or erroneous incidence. The obtained results are shown in Table 2.

  The application of the present invention is not particularly limited, but it can be particularly suitably used for optical waveguides for short to medium / long distances such as inter-device communication and intra-device communication.

Three-dimensional view showing an example of the resin film of the present invention Sectional drawing which shows an example of the width direction-thickness direction cross section of a resin film Sectional drawing which shows an example of the width direction-thickness direction cross section of a resin film Sectional drawing which shows an example of the width direction-thickness direction cross section of a resin film Cross section of composite device and flow path in composite device Plan view showing an example of the core arrangement part Plan view showing an example of the slit portion Channel diagram showing an example in the core array Plan view showing an example of the core arrangement part Composite device forming two dispersion groups and flow path cross-sectional view in the composite device

Explanation of symbols

1: Resin A
2: Resin B
3: Composite device 4: Core array part 5: Clad coating part 6: Fluid in which resin A and resin B are alternately arranged 7: Resin A
8: Side plate 9: Resin A supply part 10: Slit part 11: Resin B supply part 12: Side plate 13: Resin inlet 14: Liquid reservoir 15: Outlet 16a, 16b: Slit 17: Lower end part 18: Upper end 19: Slit ridgeline 20: Liquid reservoir bottom 21: Fluid flow direction 22: Side plate 23: Resin A supply unit 24: Slit unit 25: Resin B supply unit 26: Slit unit 27: Resin A supply unit 28: Side plate

Claims (5)

A method of manufacturing a film in which a resin A serving as a clad and a resin B serving as a core are laminated in the film width direction, and at least (a) a large number of each of the resin A serving as the clad and the resin B serving as the core pass therethrough. The resin A or the resin B is alternately and alternately arranged for each of the adjacent slits from the liquid reservoirs of the resin A and the resin B provided on the upstream side of the plurality of slits. An element A to be introduced , and (b) a plurality of laminar resin flows formed by the resin A serving as the cladding and the resin B serving as the core passing through the numerous slits merge in a predetermined order. At least a clad characterized by laminating in a film width direction in a laminating apparatus having an element B provided with a first confluence portion for forming a first laminar resin flow A resin film having a length of 2 m or more comprising a resin A and a resin B serving as a core, wherein the resin A serving as a cladding and the resin B serving as a core are thermoplastic resins. The dispersion comprising the resin B serving as a core having a structure satisfying the formulas (1) and (2) and present in the width direction of the film is 30 or more and 300 or less per 1 cm of the width direction of the film. -The manufacturing method of the resin film which is arrange | positioned substantially parallel with respect to the surface of a film at equal intervals in the cross section of thickness direction, and the thickness nonuniformity of the width direction is 15% or less.
L ≧ 1m Formula (1)
1 μm ≦ Wc ≦ 10000 μm Formula (2)
L: Length of the dispersion in the film longitudinal direction Wc: Length of the dispersion in the film width direction at the center of the dispersion In the laminating apparatus, (c) two or more of the elements A are independently present, and two or more of the elements B are independently present, and (d) is supplied to the laminating apparatus of the resin flow Each element formed in each element B, and having an element C provided with a liquid reservoir for supplying each resin stream to each element A. The first laminar resin flow merges in a predetermined order and is laminated using a laminating apparatus having an element D provided with a second merge part for forming a second laminar resin flow. The manufacturing method of the resin film of Claim 1 characterized by the above-mentioned. The method for producing a resin film according to claim 1 or 2, wherein the outermost layer serving as both ends of the film is thicker by 5 times or more than the thickness of most of the other layers. At least one surface in a direction substantially perpendicular to the laminating direction of the first layered resin flow or the second layered resin flow has a resin A that is a cladding, a resin B that is a core, or a resin different from the resin A and the resin B, or The method for producing a resin film according to any one of claims 1 to 3, wherein the resin film is coated with a resin C which is a resin obtained by mixing the resin A and the resin B. The manufacturing method of the optical film characterized by using the manufacturing method of the resin film in any one of Claims 1-4.

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