JP6473389B2 - Lens member, lens member manufacturing method, communication module, lens array, and light source module - Google Patents

Description

  The present invention relates to a lens member, a lens member manufacturing method, a communication module, a lens array, and a light source module.

  For example, a lens for optical communication is surface-mounted on a substrate (for example, a silicon bench) on which a laser diode and an end of an optical fiber are mounted, and condenses the light output from the laser diode onto the optical fiber. Things to do are known.

As such a lens, a glass lens is generally used instead of a resin lens (see, for example, Patent Document 1).
In Patent Document 1, a square lens having a square outer peripheral shape of a glass lens is used. For surface mounting on a substrate (for example, a silicon bench or the like), it is preferable that there is a flat surface (reference surface) on the outer periphery of the lens. That is, the lens can be stably placed on the mounting surface of the substrate by placing the lens so that the outer peripheral surface of the lens is in contact with the mounting surface (plane on the substrate) on which the lens of the substrate is mounted. . Also, if the arrangement relationship between the optical axis of the lens and the plane is determined, and the plane is the reference plane, the distance from the substrate to the optical axis can be determined simply by bringing the reference plane into contact with the mounting surface. become. Therefore, the square lens can be easily bonded and fixed to the mounting surface of the substrate using, for example, an ultraviolet curable resin.

  In addition, a reference surface is also provided by post-processing such as dicing and polishing on an aspherical glass lens other than the above-described square lens.

  In addition, when a polished ball lens is used, a method of sealing the ball lens with a low-melting glass to a lens barrel provided by cutting stainless steel or a nickel alloy press processed can be known. In this case, the ball lens is mounted on the substrate through the lens barrel and the can.

JP 2008-150265 A

  By the way, in the optical communication apparatus as described above, cost reduction and downsizing are required. Compared to manufacturing a glass lens that requires polishing, it is advantageous in terms of cost to manufacture a glass square lens by molding alone. Reduction is required.

  Here, some glass materials for glass ball lenses have a high melting point, and depending on the glass material, it is difficult to form a glass lens only by molding, and a glass lens that requires polishing is required. There are also many. In the case of a glass ball lens that requires this polishing, it is difficult to provide a reference surface at the time of molding like the above-mentioned square lens because there is a reference surface for polishing to a spherical shape, Since the glass lens manufactured by polishing is provided with a reference surface by post-processing such as dicing or polishing described above, it is difficult to reduce costs. At present, there is no product on the market that is intended to be mounted on the surface of a glass ball lens, which is an optical component, as a glass ball lens. There are products with an AR coating film formed.

In downsizing, in the case of the glass ball lens using the above-described lens barrel and can, the lens barrel and can interfere with downsizing and it is difficult to reduce the size. Even in the present situation, there are miniaturized products in which it is difficult to use a lens member in which a glass ball lens is attached to a lens barrel or a can due to size problems.
In this case, it is possible to mount a spherical lens (ball lens) directly on the surface by providing a V groove with a V-shaped cross section on the substrate without using a lens barrel or can, but like a ball lens. When it is a complete rotation target shape, the optical directivity is not determined until it is fixed on the substrate, and it is difficult to use the ball lens flexibly.

For example, when the AR coating is applied to the surface of the ball lens as described above, the surface on which the light is actually incident and the surface on which the light is emitted are not determined until they are mounted on the substrate. It is necessary to apply AR coating to the entire surface. In this case, since the ball lens is mounted on the substrate, when the ball lens is handled, it cannot be handled while avoiding the AR coating applied to the entire surface. For example, the AR coating may be damaged. In this case, if a scratch on the AR coating is disposed on a portion of the ball lens used for light incidence or emission, there is a risk that the yield may be reduced or the optical characteristics may be deteriorated. For example, in the case of using the glass square lens, the lens barrel, or the can described above, the surface on which the AR coating is required is clear, and the AR coating may be applied before the glass lens is surface-mounted. It is possible to handle the lens avoiding that part.
That is, it is not practical to use the ball lens alone without sealing the lens barrel or can from the viewpoints of handling at the time of mounting, handling of automatic mounting, handling at the time of bonding to the substrate, and the like.

  The present invention has been made in view of the above circumstances, and a lens member in which a mounting portion (molded body) for attaching the glass lens is added to a ready-made glass lens, a manufacturing method of the lens member, a communication module, and a lens An object is to provide an array and a light source module. It is another object of the present invention to provide an optical communication module that suppresses spherical aberration that inevitably occurs due to the ball lens itself when a ball lens is used as the glass lens, and a method for manufacturing the optical communication module.

  In order to achieve the above object, the lens member of the present invention is made of a glass lens that has already been formed, and the glass lens is made of a material different from the glass lens, and can flow into a mold in which the glass lens is disposed. A mounting portion provided by inflowing and solidifying the material in a state, and the mounting portion is provided with a reference surface that comes into contact with the mounting surface when the glass lens is surface-mounted. Features.

  According to such a configuration, even if the glass lens is, for example, a spherical lens or an aspheric lens, the glass lens is basically manufactured as a glass lens by molding or polishing (including true sphere processing), and is subjected to dicing, polishing, or the like. Without post-processing, a lens designed and manufactured so as not to cost as much as possible can be used as a single glass lens.

  Moreover, as a mounting part, for example, a state where the glass lens is fixed in a mold (mold) and manufactured by injection molding a resin, or a state where the glass lens is fixed in a mold Thus, it is conceivable that a fluid material before or after solification is introduced into a mold and manufactured as glass or ceramic by a sol-gel method. In these cases, the mounting portion is made of a material different from that of the glass lens. The mounting portion is provided so as to cover the glass lens to the extent that it does not come off the glass lens in a state where the light incident and exit portions are exposed when the lens member is used. For example, the glass lens is provided in a columnar shape that is short in the axial direction with a part of the glass lens included therein, and a planar reference surface is provided on the outer peripheral surface of the substantially columnar mounting portion.

  In the sol-gel method, for example, after injecting a sol-like material that has been made into a solution or from a solution into a mold, if the material is in a solution state, the material is made into a gel after being made into a sol. In this case, the material may be gelled and the gel may be dried by heating at a relatively low temperature (for example, 100 degrees or less). Also in this case, for example, a mounting part having a reference surface can be provided integrally with the glass lens at low cost by glass or ceramic manufactured by a sol-gel method.

The said structure of this invention WHEREIN: It is preferable that the said mounting part has a lens part which covers the light transmissive area | region of the said glass lens surface at least.
According to such a configuration, it is possible to reduce the spherical aberration of the glass lens. That is, the spherical surface of the optical system can be reduced by bringing one surface of the lens portion into close contact with the glass lens surface and setting the other surface with an aspheric shape that corrects spherical aberration caused by the glass lens.
Moreover, although it is preferable to provide a lens part in any one of the entrance surface or the output surface of a glass lens, you may provide it on both surfaces. The lens portion is preferably provided on a surface having a large NA of the incident surface or the emitting surface, for example, the laser light irradiation side, when light is actually incident on the lens member. Since the lens surface is made of resin, the phenomenon that the focal position changes due to temperature changes and the optical characteristics deteriorate occurs, but with this configuration, the lens surface made of resin is closer to the parallel light. Therefore, it is possible to suppress deterioration of optical characteristics.

The said structure of this invention WHEREIN: It is preferable that it is circular when the said glass lens is seen from a direction perpendicular | vertical from an optical axis.
According to such a configuration, for example, when the mounting part is manufactured by press molding, the glass lens disposed in the cavity of the mold is pressed and molded in the cavity. Certainly, the molding accuracy can be improved.

  The said structure of this invention WHEREIN: It is preferable that the said glass lens is a ball lens.

  According to such a configuration, the manufacturing cost of the glass ball lens can be reduced. That is, although it depends on the roundness, for example, when a glass ball lens is manufactured by a general sphere processing for creating a ball or the like of a bearing, the cost of the glass ball lens can be reduced. . That is, even if the spherical processing is basically polishing processing, many glass balls can be processed at a time, and the manufacturing cost of the lens member can be reduced compared to the case where a molded aspheric lens or the like is used as a glass lens. Can be reduced.

  Further, in the configuration of the present invention, the mounting portion is formed in a polygonal column shape including a part of the glass lens, and at least of three or more planes constituting an outer peripheral surface of a polygonal cross section of the mounting portion. It is preferable that a hole extending from the plane to the surface of the glass lens is formed in a portion where the thickness of the mounting portion is reduced by bringing the one plane and the surface of the glass lens close to each other.

  According to such a configuration, for example, when the mounting portion is a square tube-shaped member having a square cross section, when the length of each side of the square of the cross section is brought close to the diameter of the glass lens, The surface of the glass lens is close to each of the four outer peripheral surfaces of the outer periphery, and a portion with a reduced thickness is generated in the mounting portion. If the thickness of this part becomes too thin, the strength decreases, and the part where the thickness becomes thin may be broken, for example, to be broken and peeled off from the glass lens.

  Therefore, by providing a hole in the portion where the thickness is reduced, the mounting portion can be prevented from being broken at the portion where the thickness is reduced by providing a configuration in which there is no portion where the thickness is reduced. Note that this hole is preferably provided when the mounting portion is created instead of post-processing. For example, a convex portion reaching the surface of the glass lens is provided on the inner surface of the mold corresponding to the above-described plane, and the convex portion is formed. It is preferable that the hole is provided when the portion is removed.

  In addition, at least one of the outer peripheral planes of the mounting portion described above is a portion that is fixed to the mounting surface of the substrate by adhesion or the like as a reference surface, for example, when the lens member is surface-mounted on the substrate. If the reference surface has a thin and fragile portion, the portion may be broken when the portion is bonded to the substrate, and the lens member may be peeled off from the substrate. Therefore, by adopting a structure in which this portion does not start from the beginning, it is possible to suppress the lens member from falling off the substrate. In addition, when an ultraviolet curable resin is used for bonding, the amount of the resin can be increased and the bonding can be strengthened by filling the hole with the ultraviolet effect resin. In this case, the ultraviolet curable resin filled in the holes is in contact with both the mounting surface of the substrate and the surface of the glass lens, thereby directly bonding the substrate and the glass lens. Thereby, adhesion can be made stronger.

  Further, in the configuration of the present invention, the surface of the glass ball lens from the reference surface to a portion where the thickness of the mounting portion becomes thin due to the proximity of the reference surface of the mounting portion and the surface of the glass lens. It is preferable that a hole leading to is formed.

  According to such a configuration, as in the case where the plane on which the hole is formed as described above is the reference surface, the mounting portion is broken at the reference surface fixed to the mounting surface of the substrate, and the lens member Can be prevented from falling off the substrate. In addition, by injecting adhesive into the hole, the amount of adhesive used can be increased and adhesion can be strengthened, and the glass lens and substrate can be directly bonded by the adhesive in the hole. become. When the adhesive is an ultraviolet curable resin, for example, a hole that reaches the glass lens is provided on the surface of the mounting portion that is opposed to the glass lens, and the hole in the reference surface is inserted through the glass lens. It is preferable that the ultraviolet curable resin is configured to be irradiated with ultraviolet rays.

  Moreover, the said structure of this invention WHEREIN: It is preferable that the shortest distance between the outer surface arrange | positioned in the said mounting part of the said glass lens and the outer surface of the said mounting part is 0.1 mm or more.

  According to such a configuration, sufficient strength can be obtained by setting the thinnest portion of the mounting portion (the shortest distance between the outer surface of the glass lens and the mounting portion) to 0.1 mm or more. In addition, as described above, a portion having a thickness less than 0.1 mm may be eliminated by providing a hole in the portion where the thickness is reduced between the glass lens of the mounting portion as described above.

The lens member of the present invention includes a glass lens and a rectangular parallelepiped molded body that is molded in a state in which at least a part of the glass lens is accommodated therein, and supports the glass lens,
The molded body is provided with a mounting surface for attaching the molded body to another member,
Of the six outer surfaces of the molded body, at least two of the outer surfaces parallel to each other are a light incident surface and a light output surface with respect to the glass lens,
One of the light incident surface and the light emitting surface is provided with a lens portion having an aspheric shape integrally formed with the molded body on the surface of the glass lens.
In the configuration of the present invention, the glass lens is preferably a ball lens.

  The communication module of the present invention includes the above-described lens member, a light emitting element, and a substrate on which the lens member and the light emitting element are mounted, and transmits light from the light emitting element through the lens member. It is characterized by being incident on.

According to such a configuration, the light of the light emitting element can be condensed on the end face of the optical communication cable using the lens member as described above, and can be incident on the optical communication cable. It can contribute to improvement of assembly and cost reduction.
The light emitting element is, for example, a light emitting diode or a semiconductor laser. The optical communication cable uses, for example, an optical fiber.

The lens array of the present invention is molded in a state where a plurality of spherical glass lenses and a plurality of the glass lenses are arranged in a predetermined arrangement, and at least a part of each glass lens is accommodated therein. And a molded body that supports the plurality of glass lenses,
A lens portion having an aspheric shape integrally formed with the molded body is provided on at least one surface side of the plurality of glass lenses.

  According to such a configuration, the lens array is basically configured such that a plurality of glass lenses are supported by the molded body, and the same effect as that obtained when one glass lens is supported by the molded body is obtained. be able to. Further, the spherical aberration of each glass lens can be reduced. That is, the spherical surface of a plurality of optical systems can be reduced by setting one surface of the lens unit in close contact with the surface of each glass lens and setting the other surface with an aspherical shape that corrects spherical aberration caused by the glass lens. it can. In addition, by using, for example, a transparent resin as a molded body, light may be incident on or emitted from the glass lens through the molded body. For example, only one portion of each lens may be used. The structure exposed from a molded object may be sufficient. For example, it is possible to have a shape substantially the same as a lens array in which convex surfaces are arranged on a plate-like glass and to have substantially the same function, and it is possible to reduce the cost for such a lens array. That is, a lens array in which a plurality of glass lenses are supported by a molded body can be manufactured at a lower cost than when a plate-shaped lens array is molded or polished with glass.

  In addition, a light source module of the present invention includes the lens array described above and a plurality of light emitting elements that emit light through the lens array.

  According to such a configuration, for example, by attaching a light source device, for example, provided with a light emitting element to a lens array molded body in which glass lenses are arranged vertically and horizontally, the light of the light emitting element is irradiated through the lens array. Can do. Also in this case, as described above, for example, the cost can be reduced with respect to the lens array in which convex surfaces are arranged on plate-like glass.

  In addition, the lens member manufacturing method includes a material having a material different from that of the glass lens and having fluidity in the mold in which the glass lens that has already been arranged is placed, and is solidified by flowing the mold into the mold. A mounting portion having a reference surface that comes into contact with the mounting surface when the glass lens is surface-mounted and a lens portion that covers a light transmission region of the glass lens surface is provided.

  According to such a configuration, the lens portion having an optical correction function and the reference surface for surface mounting on the mounting surface can be integrally molded, and a manufacturing method with excellent mass productivity can be provided.

  According to the present invention, when a surface is mounted on a substrate, in a lens member having a reference surface that comes into contact with the mounting surface, a glass lens that has already been created is placed in the mold, and a material different from the glass lens is placed in the mold. By solidifying, the mounting part (molded body) having the reference surface (mounting surface) can be provided in a state fixed to the glass lens, and the glass member having the reference surface can be reduced in cost and size. it can.

It is a front view which shows the lens member of the 1st Embodiment of this invention. It is a side view which shows a lens member similarly. FIG. 2 is a cross-sectional view of a principal part showing an outline of a mold for molding a lens member. It is a principal part top view which shows the outline of the metal mold | die of the state which removed the movable metal mold | die similarly. It is principal part sectional drawing which shows the outline of the state which opened the metal mold | die similarly. It is a principal part top view which shows the outline of the metal mold | die of the state which removed the movable metal mold | die and opened the same. It is a figure which shows the lens member of the 2nd Embodiment of this invention, Comprising: (a) is a bottom view, (b) is a top view, (c) is a side view, (d) is a side view. It is a front view (back view). It is a side view which shows the modification in which the hole 1a of a lens member is not formed similarly. It is a side view which shows the lens member mounted in the board | substrate similarly. It is a front view which shows the optical communication module of the 3rd Embodiment of this invention. It is a side view showing an optical communication module. FIG. 3 is a cross-sectional view of a principal part showing an outline of a mold for molding the optical communication module. It is a principal part top view which shows the outline of the metal mold | die of the state which removed the movable metal mold | die similarly. It is principal part sectional drawing which shows the outline of the state which opened the metal mold | die similarly. It is a principal part top view which shows the outline of the metal mold | die of the state which removed the movable metal mold | die and opened the same. It is a side view which shows the optical communication module mounted in the board | substrate similarly. It is a side view which shows the optical communication module of the 4th Embodiment of this invention. It is a side view which shows the modification in which the hole 251a of an optical communication module is not formed similarly. It is a figure for demonstrating the optical communication module of the 5th Embodiment of this invention. FIG. 3 is a cross-sectional view of a principal part showing an outline of a mold for molding the optical communication module. It is a light transmission figure of the optical communication module of the 3rd Embodiment of this invention. It is a light transmission figure of the modification of the optical communication module of the 3rd Embodiment of this invention. It is a light transmission figure of the modification of the schematic which shows the communication module of the 6th Embodiment of this invention. It is the schematic which shows the communication module of the 7th Embodiment of this invention.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
First, a first embodiment of the present invention will be described.
As shown in FIGS. 1 and 2, the lens member 1 is molded in a state where a true ball processed glass ball lens (glass ball lens) 2 and a part of the ball lens 2 enter the inside. A mounting portion (molded body) 13 made of resin is provided.

  The ball lens 2 is processed so as to have a predetermined sphericity by, for example, a well-known sphericity process similar to a ball of a bearing. A ball lens 2 may be an existing product as a glass ball that has been processed into a true sphere, or a lens for glass made of a specified glass material may be processed into a sphere.

  Further, the sphericity, glass material type, diameter, etc. of the glass ball lens 2 can be arbitrarily selected, and the use of the lens member 1, the required optical performance, the size and cost of the product using the lens member 1. Etc. are determined based on the above. Moreover, the glass material which can be used is not specifically limited, Various glass materials can be used. Such a ball lens 2 is circular when viewed from the optical axis direction (diameter direction passing through the center of the ball lens 2).

  The mounting portion 13 of the lens member 1 is basically a rectangular parallelepiped, and here is a rectangular parallelepiped having a square cross section. In other words, the mounting portion 13 is a column having a square cross section that is short in the axial direction, and substantially includes the ball lens 2 inside. When the mounting portion 13 is viewed as a prismatic member having a square cross section, the four outer peripheral surfaces are rectangular with the same shape, and the remaining two surfaces are a front surface and a rear surface with respect to these four surfaces. The front surface may be a surface on which light is incident, and the back surface may be a surface on which light is emitted.

  When the mounting portion 13 is mounted on the mounting surface of the substrate, one of the four outer peripheral surfaces described above is a reference surface (mounting surface) 3 serving as a bottom surface, and the right and left sides thereof are perpendicular to the reference surface 3. The left and right side surfaces 5 are the left and right side surfaces 5 and the remaining surface parallel to the reference surface 3 is the top surface 4.

  Further, in this embodiment, the mounting portion 13 is a rectangular parallelepiped having a square cross section, and the center of the ball lens 2 is disposed at the center thereof. Any of the four surfaces (3, 4, 5) may be used as a reference surface (bottom surface: mounting surface), and any of them may be a top surface or a side surface.

  In addition, a substantially cylindrical hole 1 a centering on the center of the rectangular surface is formed in each of the reference surface 3, the top surface 4, and the left and right side surfaces 5 of the mounting portion 13.

  Further, when the length of the mounting portion 13 in the axial direction (the axis passing through the center of the front surface 6 to the center of the rear surface 7) is slightly longer than the diameter of the ball lens 2, the lens member 1 is viewed from the side surface 5 side. In addition, the length in the front-rear direction (direction from the front surface 6 to the rear surface 7) is shorter than the length in the vertical direction (direction from the reference surface (bottom surface) 3 to the top surface 4), but the length in the front-rear direction is The diameter of the ball lens 2 is slightly longer.

It is assumed that the ball lens 2 is completely buried in the mounting portion 13. That is, the outer surface of the ball lens 2 is disposed inside the six outer surfaces of the rectangular parallelepiped mounting portion 13. In the mounting portion 13, in addition to the hole 1 a described above, the front surface 6 and the rear surface 7 of the lens member 1 are exposed to the light incident surface and the light exit surface of the ball lens 2, respectively. Hole 6a and hole 7a are provided.
That is, at least two of the outer surfaces of the ball lens 2 are provided in the outer surfaces of the mounting portion 13 which are parallel to each other (front surface 6 and rear surface 7). The part is exposed from the mounting part 13.

  The hole 6 a is provided from the front surface 6 of the mounting portion 13 of the lens member 1 to the surface (outer surface) of the ball lens 2, and the hole 7 a extends from the back surface 7 of the mounting portion 13 of the lens member 1 to the surface of the ball lens 2. It is provided as follows. The diameters of these holes 6a and 7a are larger than the above-described hole 1a, but smaller than the diameter of the ball lens 2. In addition, a line segment connecting the center of the hole 6 a and the center of the hole 7 a passes through the center of the ball lens 2.

  In the present embodiment, the front surface and the back surface of the mounting portion 13 have the same shape, and either of them may be the front surface or the back surface, and which of the two spherical surfaces of the ball lens 2 exposed from the front surface and the back surface is selected. It may be an entrance surface or an exit surface.

  An AR coating film is formed on the surface (spherical surface) of the ball lens 2 exposed through the holes 6a and 7a of the mounting portion 13. Note that the center of the mounting portion 13 and the center of the ball lens 2 do not necessarily need to coincide with each other and may be shifted, but the distance between the reference surface 3 and the optical axis of the ball lens 2 is the set distance. It needs to be. Moreover, the synthetic resin which comprises the mounting part 13 is not specifically limited, A well-known thermoplastic resin and a thermosetting resin can be used. Further, in the manufacture of a product having a substrate on which the lens member 1 is surface-mounted, when there is a solder reflow process, the resin of the mounting portion 13 needs to be a heat-resistant resin that can withstand the temperature during the reflow process. is there. Further, the color of the resin may be transparent or other colors, but may be black, for example.

  According to such a lens member 1, the mounting portion 13 can be easily manufactured in a mold in which the ball lens 2 is arranged with a material different from that of the glass ball lens 2. In addition, the mounting portion 13 has a reference surface 3 that allows the lens member 1 to be placed in contact with the mounting surface (attached surface) of the substrate (other member). The lens member 1 in which the adhesive is applied to the set substrate can be automatically surface-mounted. The lens member 1 does not roll like the ball lens 2 alone, and the lens member 1 can be surface-mounted on the substrate without providing the V-groove on the mounting surface.

  Further, the ball lens 2 does not necessarily have to be polished as a glass lens, and uses a method capable of processing a large number of balls at the same time by a true sphere process similar to that of a bearing ball. A ball with high sphericity can be used. In this case, the cost of each ball lens 2 is lower than when the lenses are formed by molding or when the lenses are polished one by one. Therefore, even if it is necessary to form the mounting portion 13 after the ball lens 2 is manufactured, the cost of the lens that is surface-mounted on the substrate can be reduced.

  The mounting portion 13 is slightly longer than the diameter of the ball lens 2 in the front-rear direction, the left-right direction, and the vertical direction so that the ball lens 2 is completely embedded. It can be made much smaller than the one attached.

  Further, when the lens member 1 is reduced in size, the length of one side of the square of the cross section of the mounting portion 13 approaches the diameter of the ball lens 2. The distance between each surface (3, 4, 5) and the ball lens 2 is shortened, and each surface (3,4, 5) of the mounting portion 13 and the ball lens 2 are closest to each other at the mounting portion. The thickness of the resin constituting 13 is reduced, and there is a possibility that a necessary and sufficient strength cannot be maintained and a fragile state is caused. For example, in terms of strength, in the mounting portion 13, the shortest distance (the thinnest thickness) between the outer surface disposed in the mounting portion 13 of the ball lens 2 and the outer surface of the mounting portion 13 is 0.1 mm or more. Preferably there is. Moreover, it is preferable that the thickness of the mounting part 13 which faces the hole 1a is 0.1 mm or more.

Therefore, in order to reduce the size of the lens member 1, by providing the hole 1a in the portion close to the ball lens 2 on each surface (3, 4, 5), it is possible to remove a portion that may become fragile. preferable. For example, by adopting a structure in which the hole 1a is provided in a portion where the thickness of the mounting portion 13 as the shortest distance is thinner than 0.1 mm, the thickness can be prevented from being thinner than 0.1 mm.
Thereby, even if the lens member 1 is reduced in size, the thinned portion of the mounting portion 13 can be prevented from being broken. As a result, the lens member 1 can be further reduced in size.

  Further, when the hole 1a is provided in the reference surface 3 that comes into contact with the mounting surface, if the hole 1a is filled with, for example, an ultraviolet curable resin as an adhesive, the substrate is directly formed by the ultraviolet curable resin through the hole 1a. And the ball lens 2 can be bonded to each other, and the adhesive strength can be improved. At this time, by filling the hole 1a with an adhesive, the adhesive strength can be increased by increasing the amount of the adhesive depending on the type of the adhesive.

  Further, when the adhesive is an ultraviolet curable resin, the hole 1a is formed in the top surface 4 together with the reference surface 3, so that the ultraviolet light passes from the hole 1a on the top surface 4 to the hole 1a on the reference surface 3 through the ball lens 2. The lens member 1 can be easily adhered to the substrate.

  Note that the cross-sectional shape of the mounting portion 13 is not limited to a square. For example, in order to shorten the distance from the mounting surface to the top surface 4, the top surface 4 and the reference surface are larger than the distance between the left and right side surfaces 5. The distance between the left and right side surfaces 5 may be shorter than the distance between the top surface 4 and the reference surface 3 in order to shorten the distance to 3 or to narrow the left and right width. In this case, it is good also as what provides the hole 1a only in the long surface of each surface (3, 4, 5).

  Next, the manufacturing method of the lens member 1 of this invention is demonstrated. In manufacturing the lens member 1, a glass ball, which is a glass ball manufactured by well-known true sphere processing, is used as the ball lens 2. A resin mounting portion 13 is manufactured on the outside of the glass ball by resin molding. As the resin molding, for example, injection molding is used. In the injection molding at this time, a mold schematically shown in FIGS. 3 to 6 is used.

  The mold is configured to form a cavity 22 as a space filled with resin and molded, and a pair of molds (a fixed mold 26 and a movable mold 27) and a slide core 21 disposed therebetween. With. The slide core 21 is provided so as to reciprocate in one direction with respect to the fixed mold 26. However, the slide core 21 may be provided so as to be reciprocally movable in the movable mold 27.

  The cavity 22 is connected to a runner 24 for filling the cavity 22 with resin through a gate. The runner 24 is provided on the slide core 21, for example, and is connected to one of the four corners on the outer periphery of the cavity 22. The runner portion 24 a formed by the runner 24 after the molding is cut at the corner portion of the mounting portion 13 corresponding to the cavity 22, including the portion molded by the gate. For example, in the present embodiment, the resin molded by the gate is cut at the position of the cutting surface 25 shown in FIG. At this time, the gate mark (cutting mark) is prevented from coming out of the outer peripheral surface composed of the above-described four surfaces (3.4.5) of the mounting portion 13.

  The fixed mold 26 is provided with a ball receiving portion 23 having a spherical surface corresponding to the ball lens 2, and the ball lens 2 is placed on the spherical surface of the ball receiving portion 23. The ball lens 2 and the ball receiving portion 23 are in spherical contact with each other so that the resin filled in the cavity 22 does not enter between the ball receiving portion 23 and the ball lens 2. The ball receiving portion 23 is formed so as to protrude from a portion constituting the bottom surface of the cavity 22 of the fixed mold 26, and the ball receiving portion 23 causes a hole on the front surface (or the back surface) of the mounting portion 13 of the lens member 1. 6a (hole 7a) is formed.

  Further, four slide cores 21 are provided corresponding to the four surfaces (3, 4, 5) of the mounting portion 13 described above, and can freely reciprocate along four directions different by 90 degrees. Yes. In addition, the tip of the slide core 21 has a tip surface 32 that constitutes one of the four wall surfaces around the cavity 22, and the tip surface 32 includes each surface (3 , 4, 5) is provided with a cylindrical protrusion 29 for forming the hole 1a. In addition, the four slide cores 21 are close to each of the front end surfaces 32 so that the front end surfaces 32 form the four outer surfaces of the cavity 22, and the mounting portion 13 is molded after resin molding. When the formed lens member 1 is released and removed, the four slide cores 21 are retracted until the cylindrical convex portion 29 is completely removed from the hole 1a of the molded mounting portion 13.

  The movable mold 27 has the same shape as that of the fixed mold 26 except for the slide core 21 and is symmetrical with respect to the plane. The movable mold 27 includes a ball covering portion 28 with the ball receiving portion 23 turned upside down. . The ball covering portion 28 has a spherical surface corresponding to the ball lens 2 like the ball receiving portion 23, and this spherical surface comes into surface contact with the spherical surface of the ball lens 2 with the movable mold 27 closed. The resin filled in the cavity 22 does not enter between the ball covering portion 28 and the ball lens 2. The ball covering portion 28 is formed so as to protrude from a portion constituting the bottom surface of the cavity 22 of the fixed mold 26, and the ball covering portion 28 causes a hole on the front surface (or the back surface) of the mounting portion 13 of the lens member 1. 6a (hole 7a) is formed.

  In the molding using such a mold, first, as shown in FIGS. 5 and 6, each slide core 21 is retracted along the arrow, and the movable mold 27 is raised along the arrow to receive the ball. The ball lens 2 is placed on the spherical surface of the portion 23. Next, the slide core 21 is advanced so that the periphery of the cavity 22 is surrounded by the four tip surfaces 32 of the slide core 21 as shown in FIGS. The tip end surface of 29 is brought into contact with the ball lens 2 held by the ball receiving portion 23.

  At this time, the movable mold 27 is lowered to approach the fixed mold 26. At this time, the upper side of the cavity 22 is closed by the movable mold 27, and the ball covering portion 28 is covered with the ball lens 2. As a result, the surface on which the light of the ball lens 2 enters or exits is covered with the spherical surface of the ball receiving portion 23 and the spherical surface of the ball covering portion 28 so as not to come into contact with the flowable resin. Similarly, the resin having fluidity does not enter the contact surface between the cylindrical convex portion 29 of the slide core 21 and the ball lens 2.

With the fixed mold 26, the movable mold 27 and the four slide cores 21 closed, the resin is filled into the cavity 22 from the runner 24 through the gate.
Thereby, a rectangular parallelepiped mounting portion 13 is formed around the ball lens 2.

Next, contrary to the case described above, the movable mold 27 is raised and the slide core 21 is retracted to take out the lens member 1 on which the mounting portion 13 is molded.
According to such a manufacturing method of the lens member 1, the mounting portion 13 having the reference surface 3 is formed by resin molding around the ball lens 2 manufactured by a relatively inexpensive sphere processing as a glass lens. Therefore, it can be manufactured relatively inexpensively. That is, the cost can be reduced compared to a square lens that is a conventional molded lens made of glass or a lens member in which a ball lens is sealed in a housing or a can. In addition, the mounting portion 13 can be downsized to a size close to the diameter of the ball lens 2, and can respond to a request for downsizing of a device for optical communication, for example. For example, the length of each side of the square of the cross section of the mounting portion 13 can be set to 1 mm, 2 mm, 3 mm, etc., for example. At this time, the diameter of the ball lens 2 is set in accordance with the size of the mounting portion 13. Note that the size of the mounting portion 13 is not limited to that described above, and may be 1 mm or less or 3 mm or more.

Next, the lens member 101 according to the second embodiment will be described.
In each of the following embodiments, each lens member 101, 41, 51, 62, 71, 81 is a ball lens 2 (or an aspheric lens described later) as in the lens member 1 of the first embodiment. 72) and resin mounting portions 113, 49, 59, 69, 79, 89. The ball lens 2 is the same as that of the first embodiment, and the mounting portions 113, 49, 59, The shapes of 69, 79, and 89 are different from those of the first embodiment. In the following description, a different part from 1st Embodiment is demonstrated and description of the structure similar to 1st Embodiment is abbreviate | omitted or simplified.

As shown in FIG. 7, the mounting portion 113 of the lens member 101 is basically a rectangular parallelepiped like the first embodiment, and here is a rectangular column that is short in the axial direction of a square cross section.
When the mounting portion 113 is mounted on the mounting surface 108 (attached surface: illustrated in FIG. 9) of the substrate 109 (illustrated in FIG. 9), one of the four outer peripheral surfaces described above serves as a bottom surface. 103, the left and right side surfaces 105 are the right and left side surfaces 105, and the remaining surface parallel to the reference surface 103 is the top surface 104.

7A is a bottom view, FIG. 7B is a plan view, FIG. 7C is a side view, and FIG. 7D is a front view (or rear view).
In this embodiment, since the center of the ball lens 2 is disposed at the center of the mounting portion 113, the mounting portion 113 is a three-dimensionally symmetric solid when rotated around the axis of a square column having a square cross section. Any of the four surfaces (103, 1044, 105) may be used as a reference surface (bottom surface), and any of them may be a top surface or a side surface.

  As in the first embodiment, a substantially cylindrical hole 101a centering on the center of a rectangular surface is formed on each of the reference surface 103, the top surface 104, and the left and right side surfaces 105 of the mounting portion 113. ing. As shown in FIG. 8, the hole 101a may not be provided in the reference surface 103, the top surface 104, and the left and right side surfaces 105. The hole 101a may be provided only on the reference surface 103, may be provided only on the reference surface 103 and the top surface 104, or may be provided only on the left and right side surfaces 105. 103 is preferably provided on the reference surface 103 and the top surface 104.

  Further, the length of the mounting portion 113 in the axial direction is shorter than the diameter of the ball lens 2, for example, about the radius of the ball lens 2 or shorter than the radius. Therefore, when the center of the ball lens 2 is arranged at the center of the mounting portion 113, the ball lens 2 is exposed from the front surface 106 and the back surface 107 of the mounting portion 113. The spherical surface of the ball lens 2 that protrudes from the mounting portion 113 and is exposed serves as a light incident surface or light exit surface.

  Accordingly, at least two of the six outer surfaces (front surface 106, rear surface 107, reference surface 103, top surface 104, and left and right side surfaces 105) of the mounting portion 113 are parallel to each other, here, the ball lens 2 is disposed inside the four outer surfaces. However, the outer surface of the ball lens 2 protrudes outward with respect to the front surface 106 and the rear surface 107 which are the remaining outer surfaces. The length of the mounting portion 113 along the optical axis direction of the ball lens 2, that is, the distance between the front surface 106 and the back surface 107 is shorter than the length along the optical axis direction of the ball lens 2, that is, the diameter. become. Here, the thickness along the optical axis direction of the ball lens 2 is D, and the distance along the optical axis direction between the front surface 106 and the rear surface 107 as a pair of outer surfaces orthogonal to the optical axis of the ball lens 2 of the mounting portion 113. When T is T, it is preferable that 0.2D ≦ T. That is, if the distance T is too short with respect to the diameter D of the ball lens 2, the lens member 101 becomes unstable when the lens member 101 is mounted, and the possibility that the lens member 101 falls down is increased. The length of the portion 113 along the optical axis direction is preferably longer than 0.2 times the diameter of the ball lens 2.

  In the present embodiment, the front surface 106 and the back surface 107 of the mounting portion 113 have the same shape, and either one may be the front surface 106 or the back surface 107, and the two ball lenses 2 exposed from the front surface 106 and the back surface 107 may be used. Either of the spherical surfaces may be used as the entrance surface or the exit surface. An AR coat film is formed on the surface (spherical surface) of the ball lens 2 exposed from the mounting portion 113.

  As shown in FIG. 9, such a lens member 101 is mounted on the mounting surface 108 after being mounted on the mounting surface 108 of the substrate 109, for example. In this case, for example, an automatic surface mounting apparatus is used, and the lens member 101 is placed and fixed in a direction set to a set position (a predetermined coordinate position in the XY coordinate system) of the mounting surface 108 of the substrate 109. Is done. At this time, the reference surface 103 is in contact with the mounting surface 108 and is placed on the substrate 109 in a stable state. Further, the mounting portion 113 is bonded by, for example, an ultraviolet curable resin 110 as an adhesive. Reference numerals 111 and 112 indicate incident light or outgoing light of the ball lens 2.

Next, a third embodiment of the present invention will be described.
As shown in FIGS. 10 and 11, the lens member 201 is molded in a state in which a spherical ball lens (glass ball lens) 202 processed into a perfect sphere and a part of the ball lens 202 enter the inside. And a transparent mounting portion 213 made of resin.

  The ball lens 202 is processed to have a predetermined sphericity by, for example, a well-known sphericity process like a ball of a bearing. A ball lens 202 may be used as a ball lens 202, or a lens glass made of a specified glass material may be processed into a spherical shape.

  The sphericity, glass material type, diameter, and the like of the glass ball lens 202 can be arbitrarily selected. The use of the lens member 1, the required optical performance, the size of the product using the lens member 1, and the cost. Etc. are determined based on the above. Moreover, the glass material which can be used is not specifically limited, Various glass materials can be used.

  The mounting portion 213 of the lens member 201 is basically a rectangular parallelepiped, and here is a rectangular parallelepiped having a square cross section. In other words, the mounting portion 213 has a columnar shape with a square cross section, and substantially includes the ball lens 202 inside. When the mounting portion 213 is viewed as a prismatic member having a square cross section, the four outer peripheral surfaces are rectangles having the same shape, and the remaining two surfaces are a front surface and a rear surface with respect to these four surfaces. One of the front side and the back side of the ball lens is a light incident surface and the other is a light exit surface. Here, the front side may be referred to as a first surface and the back side may be referred to as a second surface.

  When the mounting portion 213 is mounted on the mounting surface of the substrate, one of the four outer peripheral surfaces described above is the reference surface 203 serving as a bottom surface, and the right and left sides thereof are arranged at right angles to the reference surface 203. The surface is the left and right side surfaces 205, and the surface parallel to the remaining reference surface 203 is the top surface 204.

  Further, in this embodiment, the mounting portion 213 is a rectangular parallelepiped having a square cross section, and the center of the ball lens 202 is disposed at the center thereof. Any of the four surfaces (203, 204, 205) may be the reference surface (bottom surface), and any of the four surfaces (203, 204, 205) may be the top surface or the side surface.

  In addition, a substantially cylindrical hole 201 a centering on the center of the rectangular surface is formed on each of the reference surface 203, the top surface 204, and the left and right side surfaces 205 of the mounting portion 213, and the surface of the ball lens 202 is Some are exposed.

  Further, when the length of the mounting portion 213 in the axial direction (the axis passing through the center of the front surface 206 to the center of the back surface 207) is slightly longer than the diameter of the ball lens 202, the lens member 201 is viewed from the side surface 205 side. In addition, the length in the front-rear direction (the direction from the front 206 to the back 207) is slightly longer than the diameter of the ball lens 202.

  Therefore, when viewed from the vertical direction of the optical axis, the ball lens 202 is completely embedded in the mounting portion 213 in appearance, but in addition to the hole 201a, the front surface 206 and the rear surface 207 of the lens member 201 , 206a and a hole 207a are provided for allowing incident light and outgoing light to the ball lens 202 to pass through the air in the mounting portion 213, respectively. Further, in the mounting portion 213, a lens portion 209 for giving an optical action to incident light or outgoing light is integrally formed between the hole 206a and the ball lens 202. An aspherical shape is set at least in a region where a light ray passes through a lens portion 209 made of a transparent resin made of the same material as that of the mounting portion, and the spherical aberration of the light ray transmitted through a spherical ball lens is corrected. It has a function. That is, one surface of the lens portion 209 is in close contact with the surface of the ball lens 202, and an aspheric shape is set on the other surface.

  The hole 206 a is shaped so that the diameter gradually decreases from the front surface 206 of the mounting portion 213 of the optical communication module 1 toward the first surface of the ball lens 202, and the surface of the first surface of the ball lens 202 To the lens portion 209 of the lens. On the other hand, the hole 207 a has a shape that gradually decreases in diameter from the back surface 207 of the mounting portion 213 of the lens member 201, and is provided so as to reach the surface of the ball lens 202. The diameters of these holes 206a and 207a are larger than the above-mentioned hole 201a. Further, a line segment connecting the center of the hole 206a and the center of the hole 207a is disposed so as to pass through the center of the ball lens 202, and coincides with the optical axis of the ball lens 202.

  An AR coating film is formed on the lens unit 209 facing the hole 206a of the mounting unit 213 and the surface (spherical surface) of the ball lens 2 exposed through the hole 207a. Note that the center of the mounting portion 213 and the center of the ball lens 202 do not necessarily coincide with each other and may be shifted, but the distance between the reference surface 203 and the optical axis of the ball lens 202 is the set distance. It needs to be. Moreover, the transparent synthetic resin which comprises the mounting part 213 is not specifically limited, A well-known thermoplastic resin and a thermosetting resin can be used. Further, in the manufacture of a product having a substrate on which the lens member 201 is surface-mounted, when there is a solder reflow process, the resin of the mounting portion 213 needs to be a heat-resistant resin that can withstand the temperature during the reflow process. is there.

  According to such a lens member 201, the mounting part 213 including the lens part 209 can be easily manufactured in a mold in which the ball lens 202 is arranged with a material different from that of the glass ball lens 202. In addition, since the mounting portion 213 has a reference surface 3 on which the lens member 201 can be placed in contact with the mounting surface of the substrate, for example, an adhesive is applied to the substrate set in the automatic surface mounting apparatus. The optical communication module 201 can be automatically surface-mounted. The lens member 201 can be surface-mounted on the substrate without rolling like the ball lens 202 alone and without providing the V-groove on the mounting surface. Furthermore, since the lens portion 209 for improving the optical performance is formed at the same time as the mounting portion 213 is formed, the performance as an optical component can be improved.

  The ball lens 202 does not necessarily have to be polished as a glass lens, and uses a method that can process a large number of balls at the same time, such as a true sphere process similar to that of a bearing ball. A ball with high sphericity can be used. In this case, the cost of each ball lens 2 is lower than when the lenses are formed by molding or when the lenses are polished one by one. Therefore, even if it is necessary to mold the mounting portion 213 after manufacturing the ball lens 202, the cost of the lens to be surface-mounted on the substrate can be reduced.

  Further, the mounting portion 213 is slightly longer than the diameter of the ball lens 202 in the front-rear direction, the left-right direction, and the vertical direction so that the ball lens 202 is completely embedded. It can be made much smaller than the one attached.

  Further, when the size of the lens member 201 is reduced, the length of one side of the square of the cross-section of the mounting portion 213 approaches the diameter of the ball lens 2. The distance between each surface (203, 204, 205) and the ball lens 202 is shortened, and each surface (203, 204, 205) of the mounting portion 213 is closest to the ball lens 202 at the mounting portion. There is a possibility that the resin constituting 213 becomes thin, and a necessary and sufficient strength cannot be maintained and a fragile state is caused. Therefore, in order to reduce the size of the lens member 201, by providing the hole 201a in the portion close to the ball lens 202 on each surface (203, 204, 205), a portion that may become fragile is removed. preferable. It is preferable that the thickness of the mounting portion 13 facing the hole 201a is 0.1 mm or more.

Thereby, even if the lens member 201 is downsized, the thinned portion of the mounting portion 213 can be prevented from being broken. As a result, the lens member 201 can be further reduced in size.
Further, when the hole 201a is provided in the reference surface 203 that is in contact with the mounting surface, if the hole 201a is filled with, for example, an ultraviolet curable resin as an adhesive, the substrate is directly formed by the ultraviolet curable resin through the hole 201a. Can be bonded to the ball lens 202, and the adhesive strength can be improved. At this time, by filling the hole 201a with an adhesive, the adhesive strength can be increased by increasing the amount of the adhesive depending on the type of the adhesive.

  Further, when the adhesive is an ultraviolet curable resin, a hole 201a is formed in the top surface 204 as well as the reference surface 203, so that an ultraviolet ray passes through the ball lens 202 from the hole 201a in the top surface 204 to the hole 201a in the reference surface 203. The lens member 201 can be easily adhered to the substrate.

  Note that the cross-sectional shape of the mounting portion 213 is not limited to a square. For example, in order to shorten the distance from the mounting surface to the top surface 204, the top surface 204 and the reference surface are more than the distance between the left and right side surfaces 205. The distance between the left and right side surfaces 5 may be shorter than the distance between the top surface 204 and the reference surface 203 in order to shorten the distance to 203 or to narrow the left-right width. In this case, the hole 201a may be provided only on the longer one of the surfaces (203, 204, 205).

  Alternatively, the hole 201a may be provided only in the reference surface 203. In this case, an adhesive is injected into the hole 201a facing the reference surface 203 and adhered to the mounting surface. Even in this case, since the resin of the mounting portion 213 is transparent, it can be cured even if the adhesive is an ultraviolet curable resin. At this time, it is preferable that the surface of the ball lens 202 is in contact with the reference surface 203 when it is assumed that there is no hole 201a, or the surface of the ball lens 202 exists slightly inside the reference surface 203. That is, the surface of the ball lens 202 is disposed so as not to protrude with respect to the reference surface 203. The shortest distance between the optical axis and the surface of the ball lens 202 and the reference surface 203 is preferably 0 or more and 0.5 mm or less, and more preferably 0.05 mm or more and 0.3 mm or less. By defining the position of the ball lens in this way, fluctuations in the height of the lens optical axis due to expansion / contraction of the mounting portion 213 due to temperature changes can be suppressed, and bonding with a sufficient adhesive can be performed. it can.

  Next, the manufacturing method of the lens member 201 of this invention is demonstrated using FIGS. In the manufacture of the optical communication module 201, a glass ball, which is a glass ball manufactured by well-known true sphere processing, is used as the ball lens 202. A resin mounting portion 213 is manufactured on the outside of the glass ball by resin molding. As the resin molding, for example, injection molding is used. In the injection molding at this time, a mold schematically shown in FIGS. 12 to 14 is used.

  The mold is configured so as to form a cavity 222 as a space filled with resin, and a pair of molds (a fixed mold 226 and a movable mold 227) and a slide core 221 disposed therebetween. With. The slide core 221 is provided so as to reciprocate in one direction with respect to the fixed mold 226, but may be provided so as to be reciprocally movable in the movable mold 227.

  The cavity 222 is connected to a runner 224 that fills the cavity 222 with resin through a gate. The runner 224 is provided on the slide core 221, for example, and is connected to one of the four corners on the outer periphery of the cavity 222. The runner part 224a formed by the runner 224 after the molding is cut at the corner of the mounting part 213 corresponding to the cavity 222, including the part molded by the gate. For example, in the present embodiment, the resin molded by the gate is cut at the position of the cut surface 225 shown in FIG. At this time, the gate mark (cutting mark) does not protrude outside the outer peripheral surface formed by the above-described four surfaces (203, 204, 205) of the mounting portion 213.

  The fixed mold 226 is provided with a ball receiving portion 223 having a spherical surface corresponding to the ball lens 202, and the ball lens 202 is placed on the spherical surface of the ball receiving portion 223. The ball lens 202 and the ball receiving portion 223 are in spherical contact with each other so that the resin filled in the cavity 222 does not enter between the ball receiving portion 223 and the ball lens 202. The ball receiving portion 223 is formed so as to protrude from a portion constituting the bottom surface of the cavity 222 of the fixed mold 226, and the hole 207 a on the back surface of the mounting portion 213 of the lens member 201 is formed by the ball receiving portion 223. It is like that.

  Further, four slide cores 221 are provided corresponding to the four surfaces (203, 204, 205) of the mounting portion 213, and can reciprocate along four different directions by 90 degrees. Yes. The slide core 221 has a distal end surface 232 that constitutes one of the four wall surfaces around the cavity 222 at the distal end, and the distal end surface 232 includes each surface (203 of the outer periphery of the mounting portion 213). , 204, 205) is provided with a cylindrical convex portion 229 for forming the hole 201a. In addition, the four slide cores 221 have their front end surfaces 232 brought close to each other, and the front end surfaces 232 are moved forward to form the four outer surfaces of the cavity 222, and the mounting portion 213 is formed after resin molding. When the formed members 201 are released and taken out, the four slide cores 221 are retracted until the cylindrical convex portion 229 is completely removed from the hole 201a of the molded mounting portion 213.

  The movable mold 227 has a shape that is substantially plane-symmetric with the fixed mold 226 except for the portion of the slide core 221, and a lens portion forming section 228 having a shape in which the ball receiving section 223 is turned upside down. Is provided. The lens part forming part 228 constitutes a cavity for forming the lens part 209 on the ball lens 202, and has an aspheric surface corresponding to the lens part 209 in at least a light transmission region. By filling the cavity defined by the ball lens 202 and the lens portion forming portion 228 with resin, a lens portion 209 having an aspheric lens surface is formed. The ball receiving portion of the fixed mold is configured so that the resin filled in the cavity does not enter the surface of the ball lens 202, whereas the lens portion forming portion 228 of the movable mold is made of resin filled in the cavity. It is configured to be introduced on the surface of the ball lens 202. The lens portion forming portion 228 is formed so as to protrude from a portion constituting the bottom surface of the cavity 222 of the fixed mold 226, and the front surface (or the back surface) of the mounting portion 213 of the optical communication module 201 by the ball covering portion 228. The hole 206a is formed.

  In molding with such a mold, first, as shown in FIGS. 14 and 15, each slide core 221 is retracted along the arrow, and the movable mold 227 is raised along the arrow to receive the ball. The ball lens 202 is placed on the spherical surface of the portion 223. Next, the slide core 221 is advanced so that the periphery of the cavity 222 is surrounded by the four tip surfaces 232 of the slide core 221 as shown in FIGS. The tip surface of 229 is brought into contact with the ball lens 202 held by the ball receiving portion 223.

  At this time, the movable mold 227 is lowered to approach the fixed mold 226. At this time, the upper side of the cavity 222 is closed by the movable mold 227 and the lens part forming part 228 is put on the ball lens 202. As a result, the resin flows into the space between the first surface of the ball lens 202 and the lens portion forming portion 228. On the other hand, the second surface of the ball lens 202 is covered with the spherical surface of the ball receiving portion 223 so as not to come into contact with the resin in a flowable state. Similarly, the resin having fluidity does not enter the contact surface between the cylindrical convex portion 229 of the slide core 221 and the ball lens 202. It is difficult to prevent the resin from completely flowing, and the shape and molding conditions are set so that at least the light does not flow into the transmission region.

With the fixed mold 226, the movable mold 227, and the four slide cores 221 closed, the resin is filled into the cavity 222 from the runner 224 through the gate.
Thereby, a rectangular parallelepiped mounting portion 213 is formed around the ball lens 202.

  Next, contrary to the case described above, the movable mold 227 is raised and the slide core 221 is retracted to take out the lens member 201 on which the mounting portion 213 is molded.

  According to such a manufacturing method of the lens member 1, the mounting portion 213 having the reference surface 3 is formed by resin molding around the ball lens 202 manufactured by a relatively inexpensive sphere processing as a glass lens. Therefore, it can be manufactured relatively inexpensively. That is, the cost can be reduced compared to a square lens that is a conventional molded lens made of glass or a lens member in which a ball lens is sealed in a housing or a can. In addition, the mounting portion 213 can be downsized to a size close to the diameter of the ball lens 202. For example, the mounting portion 213 can meet a demand for downsizing a device for optical communication. For example, the length of each side of the square of the cross section of the mounting portion 213 can be set to 1 mm, 2 mm, 3 mm, or the like, for example. At this time, the diameter of the ball lens 202 is set in accordance with the size of the mounting portion 213. Note that the size of the mounting portion 213 is not limited to that described above, and may be 1 mm or less or 3 mm or more.

  In addition, since the lens portion 209 is provided as a part of the mounting portion on one of the entrance surface and the exit surface of the ball lens 202, the spherical aberration of the ball lens 202 can be appropriately corrected. FIG. 21 shows a state in which spherical aberration that can be fundamentally generated in the true ball lens 202 is corrected and collected by the lens unit 209 of the aspherical lens. Table 1 shows lens data of each lens surface of the lens system 101 of this example. The lens data includes the radius of curvature, surface spacing, and refractive index of each surface. A surface marked with “*” indicates an aspherical surface. In Table 1, the first surface represents the lens surface of the mounting portion, and the second surface and the third surface represent the surface of the glass lens. The lens surface of the mounting portion is polycarbonate, and the glass lens is BK7.

  The aspherical shape adopted for the lens surface of the first surface is 4th order, 6th order, 8th order, where Y is the sag amount, c is the reciprocal of the radius of curvature, K is the conic coefficient, and h is the height of the light beam from the optical axis. When the 10th, 12th, 14th, and 16th aspheric coefficients are A4, A6, A8, A10, A12, A14, and A16, respectively, they are expressed by the following equations.

Table 2 shows the aspheric coefficients for defining the aspheric shape of the first surface of this example. In Table 2, for example, “−2.1058E-03” means “−2.1058 × 10 ⁻³ ”.

The focal length of this example was 4.812 mm, and the F number was 1.203.
In the present embodiment, the lens portion 209 of the mounting portion 213 is provided on the side on which the parallel light of the ball lens 202 is incident or emitted, but is provided on the side on which the diverging / converging light is incident or emitted as shown in FIG. However, spherical aberration caused by the ball lens can be corrected. Alternatively, the lens portions 209 may be provided on both the entrance surface and the exit surface.

  In this embodiment, since the lens portion 209 of the mounting portion 213 is provided on the side where the parallel light of the ball lens 202 is incident or emitted, deterioration of the temperature characteristics due to the resin lens portion 209 can be suppressed. .

  As described above, the lens portion is preferably provided on either the entrance surface or the exit surface of the glass lens, but may be provided on both surfaces. As shown in FIGS. 21 and 22, when one of the incident light and the emitted light is collimated light and the other is convergent or divergent light, it is preferably provided on the collimated light side as shown in FIG. That is, it is preferable to provide a lens portion on the surface having a large NA of the entrance surface or the exit surface, for example, the laser light irradiation side when light is actually incident on the lens member. Since the lens surface is made of resin, the phenomenon that the focal position changes due to temperature changes and the optical characteristics deteriorate occurs, but with this configuration, the lens surface made of resin is closer to the parallel light. Therefore, it is possible to suppress deterioration of optical characteristics.

As shown in FIG. 16, such an optical communication module 201 is mounted on the mounting surface 208 after being mounted on the mounting surface 208 of the substrate 209, for example. At this time, for example, an automatic surface mounting apparatus is used, and the optical communication module 201 is placed in a direction set at a set position (a predetermined coordinate position in the XY coordinate system) of the mounting surface 208 of the substrate 209. Fixed. At this time, the reference surface 203 is in contact with the mounting surface 108 and is placed on the substrate 209 in a stable state. Further, the mounting portion 213 is bonded with, for example, an ultraviolet curable resin as an adhesive. Reference numerals 211 and 212 indicate incident light or outgoing light of the ball lens 202.
In this example, the holes 201a are formed in the outer peripheral surfaces (203, 204, 205) of the mounting portion 213, but the holes 201a are provided in the outer peripheral surfaces (203, 204, 205) of the mounting portion 213. It is good as there is nothing.

Next, the lens member of 4th Embodiment is demonstrated.
In each of the following embodiments, each of the lens members 251 and 281 is composed of a ball lens 202 and resin mounting portions 263 and 289 as in the lens member 201 of the third embodiment. The lens 202 is the same as that of the third embodiment, and the shapes of the mounting portions 263 and 289 are different from those of the third embodiment. In the fourth embodiment, the mounting portion 213 constituting the hole 207a in the third embodiment is shortened in the axial direction so that the hole 207a is not formed. In the following description, a different part from 3rd Embodiment is demonstrated, description of the structure similar to 3rd Embodiment is abbreviate | omitted or simplified.

As shown in the side view of FIG. 17, the mounting portion 253 of the lens member 251 is basically a rectangular parallelepiped as in the third embodiment. The second surface side of the lens is exposed to the outside as viewed from the side surface.
When the mounting portion 253 is mounted on the mounting surface 2 of the substrate, one of the four outer peripheral surfaces described above is the reference surface 253 serving as a bottom surface, and the right and left sides thereof are disposed at right angles to the reference surface 253. The left and right side surfaces 255 are left and right, and the surface parallel to the remaining reference surface 253 is the top surface 254.

  Further, in this embodiment, since the center of the ball lens 202 is disposed at a position displaced in the axial direction from the center of the mounting portion 263, when the mounting portion 263 is rotated around the axis of the quadrangular prism having a square section. It is a four-fold symmetric solid, and any of the four surfaces (253, 254, 255) may be the reference surface (bottom surface), and any of the surfaces may be the top surface or the side surface.

  Similarly to the third embodiment, a substantially cylindrical hole 251a centering on the center of the rectangular surface is formed on each of the reference surface 253, the top surface 254, and the left and right side surfaces 255 of the mounting portion 2633. However, as shown in FIG. 18, the holes 251 a may be provided only on the reference surface 253 and the top surface 254, and not provided on the left and right side surfaces 255. The hole 251a may be provided only on the reference surface 253, may be provided only on the reference surface 251 and the top surface 254, or may be provided only on the left and right side surfaces 255. It is preferably provided on the surface 253 or on the reference surface 253 and the top surface 254.

  Further, the axial length of the mounting portion 263 is shorter than the diameter of the ball lens 202, and the ball lens 202 is exposed from the back surface 257 of the mounting portion 113. The spherical surface of the ball lens 202 that protrudes from the mounting portion 263 and is exposed serves as a light incident surface or light exit surface.

  In the present embodiment, the front surface 256 and the back surface 257 of the mounting portion 263 have different shapes, and either one may be the front surface 256 or the back surface 257, and two of the ball lenses 202 exposed from the front surface 256 and the back surface 257 may be used. Either of the spherical surfaces may be used as the entrance surface or the exit surface. An AR coating film is formed on the surface (spherical surface) of the ball lens 202 exposed from the mounting portion 113.

Next, the lens member 281 of the fifth embodiment will be described.
As shown in FIG. 19, the lens member 281 is manufactured so as to take a large number of a plurality of optical communication modules 281. For example, a portion to be a plurality of mounting portions 289 is formed into a single plate shape. The portion 282 is molded, and at the time of molding, a plurality of ball lenses 202 are arranged vertically and horizontally in a matrix. In the present embodiment, the ball lenses 202 are arranged in two horizontal rows and four vertical rows in the molded portion 282, but the number of vertical and horizontal rows can be arbitrarily set.

  By cutting according to the vertical and horizontal rows so as to separate the ball lenses 202 from the state at the time of molding, the individual lens members 281 are used separately. The shape of the mounting portion 289 is a shape in which the hole 201a is not provided in each surface (203, 204, 205) of the mounting portion 213 in the third embodiment. As for the shape of the mounting portion 289, a lens portion is provided on the first surface of the ball lens 202 in the same manner as the mounting portion 213 in the third embodiment. The manufacturing of the mounting portion 289 requires a cutting process after molding. However, many lens members 281 can be molded by one molding, and cost can be reduced.

  The manufacturing method of the optical communication module of this embodiment is demonstrated using FIG. The mold is composed of a fixed mold 271 and a movable mold 272. The fixed mold 271 is provided with a hemispherical recess for accommodating the ball lens 202, and the depth of the recess is set to be the same as or slightly smaller than the radius of the ball lens 202. When the movable mold 272 is combined with the fixed mold 271, a lens part is formed on the surface of the ball lens 202, and a cavity for forming a molding part 282 is formed. A mounting portion 289 is formed around the ball lens 202 by filling the cavity with a transparent resin. A plurality of lens members 281 are obtained by cutting after molding.

  In each of the above-described embodiments, the mounting portion is manufactured by molding a synthetic resin. However, the mounting portion may be manufactured by glass (ceramic) by a sol-gel method. In this case, the mold for forming the mounting portion is filled with a glass material having fluidity before or after sol formation, and then sol- lation and gelation or gelation are performed. Thereafter, the mounting part is manufactured by heating and drying.

  Further, the lens member of each of the above-described embodiments has been described on the assumption that the lens member is disposed on the substrate. However, the lens member of the present invention is also applicable to an optical element that is not disposed on the substrate. For example, the present invention can be applied to an optical module in which a semiconductor light emitting element and a lens are aligned and held by a resin housing, and an optical collimating element that converts an optical signal into a parallel light beam. In addition to being used for optical communication-related devices as described above, the lens member of each embodiment can be used effectively for products other than optical communication, such as projectors and head-up displays. In addition, a lens member can be used for data transmission in the electronic circuit board. For example, the output-side lens member mounted on the surface is converted into parallel light by irradiating it with laser light from a laser diode as a light source, and this laser light is incident on the input-side lens member and condensed to receive the light. It is good also as a structure which irradiates to. The electronic circuit board has a structure capable of transmitting data by the above-described laser beam. That is, since the lens member is miniaturized, optical communication can be performed within the electronic circuit board without using an optical fiber.

Next, the lens member of 6th Embodiment is demonstrated using FIG.
FIG. 23 is a cross-sectional view of a lens member of the third embodiment in which a demultiplexing or multiplexing filter function is provided on the opposite surface side of the glass lens on which the lens portion is formed. The first surface 293 is provided with a lens portion 298 having an aspheric shape, and a filter 299 capable of demultiplexing or multiplexing a plurality of lights having different wavelengths on the surface of the second surface 294 forming a light transmission block. Is provided. A glass ball lens is exposed from the top surface 296 and the mounting surface.
Unlike the third embodiment, the lens member molding method of the present embodiment molds the top surface 296 and the reference surface 297 with a movable mold and a fixed mold, and sets the aspherical shape to the first surface 293. The second surface 294 and the remaining two surfaces having a function of combining filters are formed with a slide core.

Next, a communication module according to a seventh embodiment of the present invention will be described.
The communication module of the present embodiment uses one of the lens members of the above-described examples. Here, the lens member 101 of the second embodiment is used.

  As shown in FIG. 24, in the optical communication module, a light emitting element 331, a lens member 101, and a housing 332 that covers them are provided on a substrate 330, and a fiber fixing portion 333 that protrudes from one side surface of the housing 332 is formed. In addition, the end of the optical fiber (optical communication cable) is fixed to the fiber fixing portion 333.

  The light emitting element 331 includes, for example, a semiconductor laser, and has a light emitting point 331a at an upper end portion, and laser light is oscillated from the light emitting point 331a. The lens member 101 is disposed so that the center position of the ball lens 2 is at the same height as the light emitting point 331 a of the light emitting element 331. The laser light oscillated from the light emitting point 331a of the light emitting element 331 is divergent light, which enters the ball lens 2 of the lens member 101 and is emitted as convergent light. The emitted light is coupled to the end face of the optical fiber 334.

  In such a communication module, use of the lens members 1, 41.51, 62, 71, 81, 101 as described above facilitates miniaturization.

DESCRIPTION OF SYMBOLS 1 Lens member 1a Hole 2 Glass ball lens (Glass lens: Ball lens: Glass ball)
3 Reference surface (bottom surface: mounting surface)
13 Mounting part (molded body)
41 Lens member 251 Lens member 253 Reference surface (bottom surface: mounting surface)
330 Substrate 331 Optical element

Claims (12)

A lens member that is surface-mounted on a substrate,
A spherical glass lens in an already produced state, and a mounting portion in a state where a resin material is formed in a polygonal column shape surrounded by a plurality of planes and integrally formed with the glass lens,
The glass lens is supported by the mounting portion in a state that is surrounded by the mounting portion and at least partially embedded in the mounting portion.
One of the flat surfaces of the mounting portion is a flat surface formed as a reference surface that comes into contact with the mounting surface when surface-mounted on the substrate,
At least one of the light incident surface and the light emitting surface of the glass lens is provided with a resin lens portion molded integrally with the mounting portion on the surface of the glass lens.
A lens member. The mounting portion is formed in a polygonal column shape including a part of the glass lens, and at least one of the three or more planes constituting the outer peripheral surface of the mounting portion in a polygonal cross section and the glass lens 2. The lens member according to claim 1 , wherein a hole extending from the flat surface to the surface of the glass lens is formed in a portion where the thickness of the mounting portion is reduced by being close to the surface. When the reference surface of the mounting part and the surface of the glass lens are close to each other, a hole from the reference surface to the surface of the glass lens is formed in a portion where the thickness of the mounting part is reduced. The lens member according to claim 1 . An outer surface disposed on the mounting portion of the glass lens, any of claims 1 to 3 in which the shortest distance between the plurality of the planes of the mounting portion and wherein the at 0.1mm or more The lens member according to claim 1 . The lens member according to claim 1, wherein an aspherical shape for correcting spherical aberration of the glass lens is formed on a surface of the resin lens portion. The mounting portion is provided in a rectangular parallelepiped shape,
2. The lens member according to claim 1, wherein an outer surface of the glass lens is disposed inside at least two of the six outer surfaces of the mounting portion that are parallel to each other.   The outer surface of the glass lens is disposed inside the six outer surfaces of the mounting portion, and at least two of the outer surfaces of the mounting portion that are parallel to each other have holes that reach the outer surface of the glass lens. The lens member according to claim 6, wherein at least two portions of the outer surface of the glass lens are exposed from the mounting portion by being provided. A lens member that is surface-mounted on a substrate, and is a spherical glass lens that has already been produced, and a polygonal columnar shape in which a resin material is surrounded by a plurality of planes and is integrally formed with the glass lens. A mounting part, and the glass lens is supported by the mounting part in a state surrounded by the mounting part and at least partially embedded in the mounting part, and one of the planes of the mounting part is When the surface is mounted on the substrate, it is a flat surface formed as a reference surface that comes into contact with the mounting surface, and at least one of the light incident surface and the light emitting surface of the glass lens is the surface of the glass lens. A method of manufacturing a lens member provided with a resin lens part molded integrally with the mounting part on the surface,
In the mold in which the already produced glass lens is disposed, the mounting portion is formed by allowing the resin material having fluidity to flow into the mold and solidifying the mold.
A method for manufacturing a lens member. A lens array surface-mounted on a substrate,
A plurality of glass ball lenses that have already been produced, and a mounting portion in which a resin material is molded into a polygonal column shape surrounded by a plurality of planes,
The plurality of ball lenses are supported by the mounting portion in a state in which the periphery is surrounded by the mounting portion and at least part of the mounting is embedded in the mounting portion.
One of the flat surfaces of the mounting portion is a flat surface formed as a reference surface that comes into contact with the mounting surface when surface-mounted on the substrate,
At least one of the light incident surface and the light emitting surface of the glass lens is provided with a resin lens portion molded integrally with the mounting portion on the surface of the glass lens.
A lens array characterized by that. A light source module comprising: the lens array according to claim 9; and a plurality of light emitting elements that emit light through the lens array. A spherical glass lens in an already produced state, and a mounting portion in a state where a resin material is formed in a polygonal column shape surrounded by a plurality of planes and integrally formed with the glass lens, The mounting portion is supported in a state surrounded by the mounting portion and at least partially embedded in the mounting portion, and one of the flat surfaces of the mounting portion is contacted with the mounting surface when being surface-mounted on a substrate. A resin lens which is a flat surface formed as a reference surface in contact with the glass lens, and is formed integrally with the mounting portion on the surface of the glass lens on at least one of the light incident surface and the light emitting surface of the glass lens A lens member provided with a portion;
The substrate on which the lens member is surface-mounted;
A light emitting element portion having a laser light source;
A fiber fixing part capable of fixing the end of the optical fiber,
The reference surface of the mounting portion is surface-mounted in contact with the mounting surface of the substrate,
The light emitting element portion and the fiber fixing portion are disposed on the substrate so that light from the laser light source of the light emitting element portion is incident on an optical fiber that can be fixed to the fiber fixing portion via the glass lens of the lens member. Located in the
  A communication module characterized by that. In a mold in which spherical glass lenses in an already produced state are arranged, a resin material having fluidity is allowed to flow into the mold and hardened, whereby the glass lens has a polygonal column shape surrounded by a plurality of planes. And a pair of outer surfaces that are parallel to each other among the plurality of planes of the mounting portion are orthogonal to the optical axis of the glass lens. A lens member provided with a resin lens portion integrally formed with the mounting portion on the surface of the glass lens on at least one of the light incident surface and the light emitting surface of the glass lens. Forming, and
As a reference surface in the case where one surface of the flat surface formed of the mounting portion is surface-mounted on a substrate, the step of contacting the mounting surface of the substrate and performing surface mounting;
The light emitting element part and the fiber fixing part are connected to the substrate so that light from a laser light source of the light emitting element part is incident on an optical fiber whose end can be fixed to the fiber fixing part via the glass lens of the lens member. Comprising the step of arranging in
A method for manufacturing a communication module.

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