WO2019039049A1 - Method for manufacturing optical communication component and optical communication component - Google Patents

Abstract

This method for manufacturing an optical communication component according to an embodiment is a method for manufacturing a spatial coupling type optical communication component, the method comprising: a step of injecting a resin from a gate into the cavity of a mold having a periodic concavo-convex structure having a depth and an interval of 100 nm or more and 1000 nm or less and provided with a lens piece portion having a diameter of 50 μm or more and 600 μm or less; and a step of curing the resin to form a lens component, wherein the proportion of a cross-sectional area of the gate to a cross-sectional area of the cavity is 50% or more and 100% or less.

Description

Method of manufacturing components for optical communication, and components for optical communication

One aspect of the present disclosure relates to a method of manufacturing an optical communication component and an optical communication component.
This application claims the priority based on Japanese Patent Application No. 2017-161518 (August 24, 2017), which is incorporated herein by reference in its entirety.

Conventionally, various components for optical communication and methods for manufacturing the same are known. Non-Patent Document 1 describes a multi-core lens optical connector capable of collectively connecting a plurality of optical fibers. A lens array composed of a plurality of lenses is provided on the end face of the optical connector. By converting the diffused light emitted from each optical fiber into parallel light by each lens of the lens array, optical coupling is performed without contacting the end face of the optical connector. In such a spatial coupling type optical connector, by performing optical coupling through a space, it is possible to suppress the adhesion of foreign matter to the end face of the optical connector while requiring a large pressing force at the time of connection. .

A method of manufacturing an optical communication component according to an aspect of the present disclosure is a method of manufacturing a spatial coupling type optical communication component, having a periodic uneven structure with a depth and a spacing of 100 nm or more and 1000 nm or less. And injecting the resin from the gate into the cavity of the mold provided with the lens frame portion having a diameter of 50 μm or more and 600 μm or less, and curing the resin to form a lens part. The ratio of the cross-sectional area of the gate to the cross-sectional area is 50% or more and 100% or less.

The component for optical communication according to one aspect of the present disclosure is a component for optical communication of space coupling type, including a lens component, and the lens component has a lens portion having a diameter of 50 μm or more and 600 μm or less, The lens portion includes a periodic uneven structure having a height and a spacing of 100 nm or more and 1000 nm or less, and the lens component is a surface on which a gate mark hardened and a gate mark is provided in the gate into which the resin is poured. The ratio of the area of the gate mark to the area of the surface is 50% or more and 100% or less.

FIG. 1 is a perspective view showing lens parts of the optical communication part of the first embodiment. FIG. 2A is a front view of the lens component of FIG. FIG. 2B is a plan view of the lens component of FIG. FIG. 3 is a cross-sectional view of the lens portion of the lens component of FIG. FIG. 4 is an enlarged cross-sectional view of the lens portion of FIG. FIG. 5 is a cross-sectional view showing a resin and a mold of the lens component of FIG. FIG. 6 is a view schematically showing a runner and a gate of the mold of FIG. FIG. 7 is a side sectional view showing an optical connector which is a component for optical communication according to the second embodiment. FIG. 8 is a cross-sectional view showing the lens array of the third embodiment. FIG. 9 is a cross-sectional view showing the lens module of the fourth embodiment. FIG. 10 is an enlarged sectional view of the lens module of FIG. FIG. 11 is a view showing the relationship between the lens diameter of the lens member, the range in which the periodic uneven structure is formed, and the beam diameter.

[Problems to be solved by the present disclosure]
In the spatial coupling type optical connector, the Fresnel loss tends to be large due to the interface having a different refractive index as compared with a PC (Physical Contact) type optical connector in which the optical fibers are in contact with each other. Therefore, since the space coupling type optical connector is more susceptible to Fresnel reflection than the PC type optical connector, there may occur a problem that the optical loss becomes large.

One aspect of the present disclosure is to provide a method for manufacturing an optical communication component capable of suppressing optical loss, and an optical communication component.

[Effect of the present disclosure]
According to one aspect of the present disclosure, light loss can be suppressed.

[Description of the embodiment]
First, the contents of the embodiments of the present disclosure will be listed and described. A method of manufacturing an optical communication component according to an embodiment is a method of manufacturing a spatial coupling type optical communication component, which has a periodic uneven structure having a depth and a spacing of 100 nm or more and 1000 nm or less Injecting the resin from the gate into the cavity of the mold provided with the lens frame portion having a diameter of 50 μm or more and 600 μm or less, and curing the resin to form the lens component, The ratio of the cross-sectional area of the gate is 50% or more and 100% or less.

The component for optical communication according to the embodiment is a component for optical communication of space coupling type, and includes a lens component, and the lens component has a lens portion having a diameter of 50 μm or more and 600 μm or less, and the lens portion is And the lens part has a surface on which a gate mark hardened and a gate mark is provided in the gate into which the resin is poured, including a periodic uneven structure whose height and spacing are 100 nm or more and 1000 nm or less. The ratio of the area of the gate mark to the surface is 50% or more and 100% or less.

In the method of manufacturing the optical communication component and the optical communication component, a lens portion having a diameter of 50 μm or more and 600 μm or less is provided. The lens portion includes a periodic uneven structure having a height and a spacing of 100 nm or more and 1000 nm or less. Fresnel reflection on the surface of the lens portion can be suppressed by the periodic uneven structure of the lens portion functioning as a moth-eye structure. Thus, light loss can be suppressed. In addition, the cross-sectional area of the gate into which the resin is poured is 50% or more and 100% or less of the cross-sectional area of the cavity. Therefore, the ratio of the area of the gate mark to the area of the surface on which the gate mark of the optical communication component is provided is 50% or more and 100% or less. Therefore, since the cross-sectional area of the gate through which the resin flows can be increased, the liquid resin can be reliably poured into the periodic uneven structure of the lens frame portion. That is, the fluidity of the liquid resin can be enhanced. Accordingly, since the resin can be reliably poured into the periodic concavo-convex structure before the liquid resin is cured, transferability of the nano-order periodic concavo-convex structure can be enhanced. Therefore, the moth-eye structure can be reliably formed in the lens portion.

In addition, the volume of the lens component may be 9 mm ³ or more and 350 mm ³ or less. Thus, even in the case of an optical communication component provided with a small lens component, the moth-eye structure can be reliably transferred to the lens portion. Therefore, lens components capable of suppressing light loss can be formed by suppressing Fresnel reflection.

The above-described component for optical communication further includes an optical fiber, an optical fiber holding member for holding the optical fiber, and a refractive index matching layer for matching the refractive index, and the optical fiber holding member holds the optical fiber. The optical fiber is fixed to the optical fiber holding member, and the tip surface of the optical fiber has a refractive index matching layer. The lens may be optically coupled to the lens portion, and positioning may be performed by inserting a guide pin into the guide hole and the hole formed in the lens part. In this case, the configuration in which the transferability of the moth-eye structure is enhanced and the light loss is suppressed can be applied to an optical fiber, an optical fiber holding member, and a component for optical communication provided with an index matching layer.

The lens component may have an abutment surface at a position closer to the end than the lens portion, and the guide hole may be formed in the abutment surface. In this case, by providing the contact surface closer to the end than the lens portion, the lens portion can be made non-contact, so spatial coupling of light can be realized.

Also, the material of the lens component may be the same as the material of the optical fiber holding member. In this case, the coefficient of thermal expansion of the lens component is the same as the coefficient of thermal expansion of the optical fiber holding member. Therefore, it is possible to suppress the positional deviation between the lens component and the optical fiber holding member due to temperature change. Therefore, it is possible to prevent the off-axis of the light due to the temperature change.

The thickness of the refractive index matching layer may be 50 μm or less. In this case, since the thickness of the refractive index matching layer is thin, it is possible to suppress displacement of the optical fiber in the connection direction of light.

The lens component may also comprise a plurality of lens portions. In this case, the pressing force required at the time of connection can be reduced by providing a plurality of lens portions and forming a multi-core optical communication component. Therefore, multi-core optical communication components can be connected efficiently.

In addition, the lens component may have a region where there is no periodic uneven structure in the outer peripheral portion. In this case, by providing the region having no periodic uneven structure in the outer peripheral portion, the alignment of the lens component can be performed with high accuracy.

Further, the component for optical communication described above may be an optical connector. In this case, it is possible to provide a spatially coupled optical connector with a small Fresnel loss.

Further, the lens component described above may be a lens array that optically couples the optical waveguide and an optical waveguide other than the optical waveguide. In this case, it is possible to obtain a spatially coupled lens array with a small Fresnel loss.

The lens component may be a lens module that optically couples the optical waveguide and the light emitting / receiving element. In this case, it is possible to provide a spatially coupled lens module with a small Fresnel loss.

Details of Embodiment
Hereinafter, specific examples of the method for manufacturing an optical communication component and the optical communication component according to the embodiment will be described with reference to the drawings. The present disclosure is not limited to the following examples, but is shown in the claims, and is intended to include all modifications within the scope of the claims and equivalents. In the description of the drawings, the same or corresponding elements will be denoted by the same reference symbols, and overlapping descriptions will be omitted as appropriate. In addition, the drawings are drawn in a simplified or exaggerated manner for ease of understanding, and the dimensions and the like are not limited to those described in the drawings.

First Embodiment
FIG. 1 is a perspective view showing a lens component 1 of the optical communication component according to the first embodiment. FIG. 2A is a front view showing the lens component 1. FIG. 2B is a plan view showing the lens component 1. The optical communication component includes, for example, a lens component 1 and an MT ferrule, and the lens component 1 is connected to the MT ferrule and the mating connector along a direction D1 which is a connection direction. The lens component 1 constitutes a space coupling type optical connector optically connected to the mating connector by being interposed between the MT ferrule and the mating connector.

The lens component 1 is, for example, a communication lens component. The lens part 1 has a substantially rectangular parallelepiped appearance. The volume of the lens component 1 is, for example, 9 mm ³ or more and 350 mm ³ or less, and the lens component 1 is small. The lens component 1 is made of a transparent resin having a high transmittance to light having a wavelength of 750 nm or more and 1650 nm or less. The lens component 1 has an end face 2a which is an abutting face in contact with the mating connector, a rear end face 2b opposite to the direction D1 of the end face 2a, and a pair of side faces 2c connecting the end face 2a and the rear end face 2b to each other. , Top surface 2d and bottom surface 2e.

The end face 2a has, for example, a rectangular shape extending along a plane orthogonal to the direction D1. The end face 2a has, for example, a long side extending in a direction D2 intersecting the direction D1 and a short side extending in a direction D3 intersecting the direction D1 and the direction D2. For example, the direction D2 is orthogonal to the direction D1, and the direction D3 is orthogonal to a plane extending in the direction D1 and the direction D2.

The end face 2a is provided with a recess 2f which is recessed in a rectangular shape in the direction D1, and a plurality of (for example, 12) lens portions 3 are formed on the bottom of the recess 2f. By providing the concave portion 2 f, the end face 2 a is provided at a position closer to the end of the lens component 1 than the lens portion 3. The lens portion 3 is a convex lens integrated with the lens component 1. The plurality of lens portions 3 are arranged along the direction D2. Guide holes 4 (holes formed in the lens component) into which guide pins for positioning the lens component 1 and the mating connector are inserted are provided on both end sides of the concave portion 2f in the direction D2.

For example, the MT ferrule described above is opposed to the rear end face 2b. The rear end face 2b, the side face 2c, the top face 2d, and the bottom face 2e are, for example, both rectangular. A gate mark 2g is provided on the upper surface 2d. The gate mark 2g is a hardened portion in the gate into which the resin constituting the lens part 1 is poured when the lens part 1 is manufactured. The gate mark 2g is provided, for example, on the rear end surface 2b side, and protrudes in a rectangular shape with respect to the upper surface 2d. For example, the gate mark 2g extends in the entire direction D2 of the upper surface 2d.

In the present embodiment, the shape of the gate mark 2g (when viewed from the direction D3) in plan view is rectangular. Gate mark 2g has a short side extending from rear end face 2b to end face 2a and a long side extending along rear end face 2b. One of the two long sides of the gate mark 2g coincides with the rear end face 2b.

The other of the two long sides of the gate mark 2g is located closer to the end face 2a than the midpoint of the short side of the upper surface 2d. Further, each of the short sides of the gate mark 2g corresponds to, for example, each side surface 2c. Therefore, the ratio of the area B of the gate mark 2g to the area A of the upper surface 2d on which the gate mark 2g is provided is 50% or more and 100% or less. The shape and size of the gate mark 2g can be changed as appropriate.

FIG. 3 is a cross-sectional view showing the lens portion 3. FIG. 4 is an enlarged sectional view of one lens portion 3. The lens portion 3 protrudes, for example, in a hemispherical shape, and the diameter R of the lens portion 3 is 50 μm or more and 600 μm or less. Each lens portion 3 includes a periodic uneven structure 3A in which a plurality of convex portions 3a are arranged in parallel on the surface. The periodic uneven structure 3A corresponds to the moth-eye structure of the lens portion 3.

By providing the lens portion 3 with the periodic uneven structure 3A, the refractive index of light passing through the lens portion 3 changes continuously from the top of the convex portion 3a toward the root of the convex portion 3a. The height H and the interval P of the convex portions 3a are 100 nm or more and 1000 nm or less. The communication wavelength of light passing through the lens portion 3 is, for example, 850 nm, 1310 nm, or 1550 nm, and the distance P and height H of the convex portions 3 a are at least 1/4 and at most 1/2 of the communication wavelength. May be

Next, the mold 5 for manufacturing the lens part 1 will be described. FIG. 5 is a cross-sectional view showing the mold 5 of the lens component 1 and the resin C constituting the lens component 1. FIG. 6 is a view schematically showing the mold 5. The mold 5 includes runners 6a and 6b through which the resin C which has been heated and liquefied is passed, a gate 7, and a cavity 8.

Further, as shown in FIGS. 3 to 5, the cavity 8 of the mold 5 has a lens frame portion 8a having a diameter R of 50 μm or more and 600 μm or less, and the lens frame portion 8a has a depth and a space Is provided with a periodic uneven structure 8 b of 100 nm or more and 1000 nm or less. The shape and size of the lens frame portion 8 a correspond to the shape and size of the lens portion 3. Further, the shape and size of the periodic uneven structure 8b correspond to the shape and size of the periodic uneven structure 3A of the lens portion 3, and the depth and interval of the periodic uneven structure 8b are periodical. The height H and the interval P of the concavo-convex structure 3A are the same.

Next, an example of a method for manufacturing an optical communication component including the lens component 1 will be described. First, after the pin 8c forming the guide hole 4 is disposed in the cavity 8 described above, as shown in FIGS. 5 and 6, the liquid resin C is injected through the runners 6a and 6b and the gate 7. (Step of injecting resin from the gate). At this time, the resin C is heated and the mold 5 is heated, for example, the temperature of the resin C is made higher than the temperature of the mold 5.

As described above, the lens component 1 has the nano-order periodic uneven structure 3A. Therefore, the fluidity of the resin C is important in order to inject the resin C into the periodic concavo-convex structure 8 b of the cavity 8 to reliably form the periodic concavo-convex structure 3 A. The fluidity of the resin C is related to the viscosity of the resin C, the temperature of the mold 5, the temperature of the resin C, the sizes of the runners 6a and 6b, and the size of the gate 7.

The temperature of the resin C and the temperature of the mold 5 are preferably higher. However, if these temperatures are close to the glass transition point (Tg), deformation at the time of taking out the lens part 1 and resin residue on the mold 5 may be concerned. Accordingly, the temperature of the resin C and the temperature of the mold 5 are preferably equal to or less than the glass transition point.

In the present embodiment, the flowability of the resin C is improved by enlarging the sizes of the runners 6 a and 6 b and the gate 7. Specifically, the ratio of the cross-sectional area F1 of the gate 7 to the cross-sectional area E1 of the cavity 8 when viewed from the direction in which the resin C flows is 50% or more and 100% or less.

Therefore, since the resin C can be injected into the cavity 8 before the temperature of the resin C decreases, the transferability of the periodic uneven structure 3A is improved. Further, by curing the resin C present in the gate 7, a gate mark 2g on the upper surface 2d of the lens component 1 is formed. As described above, the gate mark 2g is formed on the top surface 2d, but may be formed on the side surface 2c or the bottom surface 2e. That is, the gate mark 2g may be formed on a surface other than the surface orthogonal to the direction D1. In addition, since the end face 2a and the rear end face 2b of the lens component 1 are portions to be connected to the mating connector and the MT ferrule, respectively, the gate mark 2g can not be formed on the end face 2a and the rear end face 2b.

The high temperature resin C is injected from the runners 6a and 6b into the gate 7 and the cavity 8 configured as described above. The lens component 1 is formed by curing the resin C injected into the cavity 8 (step of forming the lens component). Then, the pin 8c is pulled out from the cured resin C (lens component 1), and after the cured lens component 1 is taken out from the mold 5, the lens component 1 is connected to, for example, an MT ferrule to complete an optical communication component.

Next, the method of manufacturing the optical communication component according to the present embodiment and the effects obtained from the optical communication component will be described.

In the method of manufacturing an optical communication component and the optical communication component according to the present embodiment, the lens portion 3 having a diameter R of 50 μm or more and 600 μm or less is provided. The lens portion 3 includes a periodic uneven structure 3A having a height H and a distance P of 100 nm or more and 1000 nm or less. Fresnel reflection on the surface of the lens portion 3 can be suppressed by the periodic uneven structure 3A of the lens portion 3 functioning as a moth-eye structure. Thus, light loss can be suppressed.

Further, the cross-sectional area F1 of the gate 7 into which the resin C is poured is 50% or more and 100% or less of the cross-sectional area E1 of the cavity 8. Therefore, the ratio of the area B of the gate mark 2g to the area A of the upper surface 2d where the gate mark 2g is provided is 50% or more and 100% or less. Therefore, since the cross-sectional area of the gate 7 through which the resin C flows can be increased, the liquid resin C can be reliably poured into the periodic uneven structure 8 b of the lens frame portion 8 a.

That is, since the fluidity of the liquid resin C can be enhanced, the resin C can be reliably poured into the periodic uneven structure 8 b before the liquid resin C is cured. Therefore, since the transferability of the nano-order periodic uneven structure 3A can be enhanced, the moth-eye structure can be reliably formed in the lens portion 3.

The volume of the lens component 1 is 9 mm ³ or more and 350 mm ³ or less. Thus, even if it is a component for optical communication provided with the small lens component 1, the moth-eye structure can be reliably transferred to the lens portion 3. Therefore, the lens component 1 capable of suppressing the light loss can be formed by suppressing the Fresnel reflection.

Further, the lens component 1 has an end face 2a which is a contact surface at a position closer to the end than the lens portion 3, and the guide hole 4 is formed in the end face 2a. Therefore, by providing the end face 2a closer to the end than the lens portion 3, the lens portion 3 can be made non-contact, so that spatial coupling of light can be realized.

The lens component 1 also includes a plurality of lens portions 3. Therefore, the lens component 1 includes the plurality of lens portions 3 and is a multi-core optical communication component, so that the pressing force required at the time of connection can be reduced. Therefore, multi-core optical communication components can be connected efficiently.

Second Embodiment
Next, a component for optical communication according to a second embodiment will be described with reference to FIG. FIG. 7 is a side sectional view showing an optical connector 10 which is a component for optical communication according to the second embodiment. The optical connector 10 includes the lens component 1 of the first embodiment, an optical fiber 11, an optical fiber holding member 12 for holding the optical fiber 11, and a refractive index matching layer 13 for matching the refractive index. In the following description, the description overlapping with that of the first embodiment is appropriately omitted.

The optical fiber holding member 12 is, for example, a ferrule that holds the optical fiber 11. The material of the optical fiber holding member 12 may be, for example, a transparent resin, or a resin such as PPS may contain glass. Further, the thermal expansion coefficient of the optical fiber holding member 12 may be equal to (for example, the same order of magnitude) the thermal expansion coefficient of the lens component 1. In the present embodiment, the material of the optical fiber holding member 12 is the same as the material of the lens component 1.

The optical fiber holding member 12 includes an optical end face 12 c in contact with the refractive index matching layer 13, and the refractive index matching layer 13 is provided between the optical end face 12 c and the rear end face 2 b of the lens component 1. The thickness T in the direction D1 of the refractive index matching layer 13 is, for example, 1 μm or more and 50 μm or less, and may be 20 μm or more and 50 μm or less. The optical fiber 11 has a tip surface 11 a in contact with the refractive index matching layer 13, and the tip surface 11 a is optically coupled to the lens portion 3 via the refractive index matching layer 13.

The refractive index matching layer 13 performs refractive index matching between the optical fiber 11 and the lens component 1. That is, an air layer having a large difference in refractive index is prevented from being included between the optical fiber 11 and the lens component 1. Therefore, the refractive index of the refractive index matching layer 13 is preferably a refractive index of a value between the refractive index of the optical fiber 11 and the refractive index of the lens component 1. The index matching layer 13 is, for example, an index matching sheet, an adhesive or a matching gel. The refractive index matching layer 13 may be sandwiched between the optical end face 12c and the rear end face 2b, and the sandwiched refractive index matching layer 13 may be bonded by an adhesive.

The optical fiber holding member 12 includes an optical fiber holding hole 12a extending in the direction D1, and the optical fiber 11 is held by the optical fiber holding hole 12a by inserting the optical fiber 11 into the optical fiber holding hole 12a. The direction D1 coincides with the central axis direction of the optical fiber holding hole 12a and the optical axis direction of the optical fiber 11.

The optical fiber 11 and the optical fiber holding hole 12 a are provided corresponding to the lens portion 3 of the lens component 1. The optical fiber 11 emits light L1 which is diverging light, and the lens portion 3 converts the light L1 into collimated light. In addition, the lens portion 3 may convert collimated light incident from the mating connector into light L1 which is convergent light, and the light L1 may be incident on the tip surface 11a of the optical fiber 11.

The optical fiber 11 is, for example, a single mode fiber, but may be a multi mode fiber. When the optical fiber 11 is a single mode fiber, connection loss (optical loss between the optical fiber 11 and the lens component 1 and connection loss between the optical connector 10 and another optical connector) can be suppressed more effectively. It is. For example, the plurality of lens portions 3 and the plurality of optical fibers 11 are arranged along the direction D2 (direction orthogonal to the paper surface of FIG. 7).

Guide holes 12b into which guide pins for positioning the optical connector 10 and the mating connector are inserted are formed on both ends of the optical fiber 11 in the direction D2. The guide holes 12 b communicate with the guide holes 4 of the lens component 1. Therefore, by inserting the guide pins into the guide holes 4 and the guide holes 12b, the lens component 1 and the optical fiber holding member 12 are positioned with respect to the mating connector.

The optical fiber holding member 12 is manufactured, for example, in the same manner as the method of manufacturing the lens component 1 described above. The optical fiber holding member 12 is manufactured, for example, by the mold 5. In this case, the gate mark formed by curing of the resin C in the gate 7 has a surface other than the optical end surface 12c (for example, any of the pair of side surfaces 12d Or the rear end surface facing the opposite side of the optical end surface 12c).

As described above, the optical communication component according to the second embodiment is the optical connector 10 provided with the lens component 1. Therefore, the space coupled optical connector 10 with a small Fresnel loss can be obtained. Further, in the optical connector 10, the optical fiber 11 is fixed to the optical fiber holding member 12, and the tip surface 11a of the optical fiber 11 is optically coupled to the lens portion 3 through the refractive index matching layer 13, Positioning is performed by inserting a guide pin into the hole 12 b and the guide hole 4 provided in the lens component 1. Therefore, the configuration in which the transferability of the moth-eye structure is enhanced and the optical loss is suppressed can be applied to the optical connector 10 provided with the optical fiber 11, the optical fiber holding member 12 and the refractive index matching layer 13.

Further, the material of the lens component 1 is the same as the material of the optical fiber holding member 12. Therefore, the coefficient of thermal expansion of the lens component 1 becomes equal to the coefficient of thermal expansion of the optical fiber holding member 12. Therefore, it is possible to suppress the positional deviation between the lens component 1 and the optical fiber holding member 12 due to the temperature change, so that it is possible to prevent the axial deviation of the light L1 due to the temperature change.

The optical connector 10 also includes the refractive index matching layer 13. By providing the refractive index matching layer 13, the refractive index of the optical fiber 11 and the lens component 1 can be matched. Therefore, the connection loss between the optical fiber 11 and the lens component 1 can be reduced. The thickness T of the refractive index matching layer 13 is 50 μm or less. Therefore, since the thickness T of the refractive index matching layer 13 is thin, it is possible to suppress the positional deviation of the light L1 of the optical fiber 11 in the connection direction (direction D1).

Third Embodiment
Subsequently, a third embodiment will be described with reference to FIG. In the third embodiment, the lens component is a lens array 21 in which the plurality of lens portions 3 described above are juxtaposed. In the drawings after FIG. 8, the lens component including the lens portion 3 and the configuration around it are illustrated in a simplified manner for easy understanding.

The lens array 21 optically couples, for example, the first optical waveguide 23 provided on the substrate 22 and the second optical waveguide 25 held by the holding member 24. The first optical waveguide 23 has an inclined surface 23 a that bends the optical axis of the light L 2 passing through the first optical waveguide 23 toward the lens array 21. The inclined surface 23a reflects the light L2 extending in the direction D3 in the direction D1.

For example, a refractive index matching layer 26 is interposed between the lens array 21 and the first optical waveguide 23. The material of the lens array 21 is, for example, the same as the material of the lens component 1 described above. The index matching layer 26 has the same configuration as the index matching layer 13 described above. The plurality of lens portions 3 of the lens array 21 are arranged along the direction D2 (direction orthogonal to the paper surface of FIG. 8).

The plurality of lens portions 3 are provided on the bottom surface 21 c of the recess 21 b recessed in the direction D1 with respect to the surface 21 a of the lens array 21 facing the holding member 24. Therefore, the first optical waveguide 23 and the second optical waveguide 25 are optically coupled to each other through the space K1. The holding member 24 may have, for example, the same configuration as the optical fiber holding member 12, and the second optical waveguide 25 may be similar to the optical fiber 11.

The lens array 21 is manufactured in the same manner as the method for manufacturing the lens component 1. The lens array 21 is manufactured by, for example, a mold 5. Specifically, the lens array 21 is formed by injecting the resin C from the gate 7 whose cross-sectional area F2 is 50% or more and 100% or less of the cross-sectional area E2 of the cavity 8 and curing the resin C. A gate mark formed by curing of the resin C in the gate 7 is formed on a surface other than the surface 21a and the bottom surface 21c (for example, a surface orthogonal to the paper surface of FIG. 8 or a surface directed in the left-right direction of FIG. 8).

As described above, in the third embodiment, the lens component is the lens array 21 that optically couples the first optical waveguide 23 and the second optical waveguide 25 different from the first optical waveguide 23. By including the lens portion 3 in the lens array 21, it is possible to provide a spatially coupled lens array 21 with a small Fresnel loss. Further, since the lens array 21 includes the lens portion 3 of the first embodiment, Fresnel reflection on the surface of the lens portion 3 can be suppressed.

Furthermore, since the cross-sectional area F2 of the gate 7 into which the resin C is poured is 50% or more and 100% or less of the cross-sectional area E2 of the cavity 8, the flowability of the resin C can be enhanced. Therefore, since the transferability of the nano-order periodic uneven structure 3A can be enhanced, the same effect as that of the first embodiment can be obtained.

Fourth Embodiment
Next, a fourth embodiment will be described with reference to FIG. 9 and FIG. In the fourth embodiment, the lens component is a lens module 31 in which a plurality of lens portions are juxtaposed. The lens module 31 optically couples, for example, the light emitting / receiving element 33 provided on the substrate 32 and the optical waveguide 35 held by the holding member 34.

The light emitting / receiving element 33 is mounted on the substrate 32. The light emitting / receiving element 33 is a light receiving element that converts an optical signal into an electrical signal, or a light emitting element that converts an electrical signal into an optical signal. As the light emitting / receiving element 33, PD (Photo Diode) which is a light receiving element, or LD (Laser Diode) which is a light emitting element or a Vertical Cavity Surface Emitting Laser (VCSEL) can be mentioned. The light emitting / receiving element 33 receives the light L3 or emits the light L3.

The material of the lens module 31 is, for example, the same as the material of the lens component 1 described above. The lens module 31 includes a first lens portion 31a facing the light emitting / receiving element 33, a second lens portion 31b facing the optical waveguide 35, and a portion between the first lens portion 31a and the second lens portion 31b in the light path of the light L3. And the inclined surface 31c located in

For example, the lens module 31 includes a plurality of first lens portions 31a and a plurality of second lens portions 31b juxtaposed in the direction D2 (direction orthogonal to the sheet of FIG. 9 and FIG. 10). The plurality of light emitting and receiving elements 33 are provided along the direction D2, and the plurality of light emitting and receiving elements 33 correspond to the first lens portion 31a and the second lens portion 31b.

The light L3 passing through the first lens portion 31a is bent at the inclined surface 31c and enters the second lens portion 31b. For example, the light L3 which is diverging light from the light emitting / receiving element 33 is converted into collimated light by the first lens portion 31a, reflected by the inclined surface 31c, and converted into convergent light by the second lens portion 31b. It will be incident. On the other hand, the divergent light from the optical waveguide 35 is converted into collimated light by the second lens portion 31 b, reflected by the inclined surface 31 c, converted into convergent light by the first lens portion 31 a, and enters the light emitting / receiving element 33. The plurality of first lens portions 31a are provided on the bottom surface 31f of the recess 31e which is recessed in the direction D1 with respect to the surface 31d of the lens module 31 facing the substrate 32. Therefore, the first lens portions 31a and the light emitting and receiving elements 33 are optically coupled to each other through the space K2.

Each of the first lens portion 31a and the second lens portion 31b has, for example, the same configuration as the lens portion 3 described above. That is, each of the first lens portion 31a and the second lens portion 31b has the same periodic uneven structure as the periodic uneven structure 3A. Further, each of the holding member 34 and the optical waveguide 35 may have the same configuration as each of the optical fiber holding member 12 and the optical fiber 11.

The lens module 31 is manufactured in the same manner as the lens component 1 and is manufactured, for example, by the mold 5. The lens module 31 is formed by injecting the resin C from the gate 7 whose cross-sectional area F3 is 50% or more and 100% or less of the cross-sectional area E3 of the cavity 8 and curing the resin C. A gate mark formed by curing of the resin C is formed on a surface other than the surface through which the light L3 passes (for example, a surface directed to the front side or the back side in the direction perpendicular to the paper surface of FIG. 10).

As described above, in the fourth embodiment, the lens component is the lens module 31 that optically couples the light guide 35 and the light emitting / receiving element 33. By providing the first lens portion 31a and the second lens portion 31b similar to the lens portion 3, the lens module 31 can be a spatially coupled lens module 31 with a small Fresnel loss.

Therefore, Fresnel reflection on the surface of each of the first lens portion 31a and the second lens portion 31b can be suppressed. Moreover, since the cross-sectional area F3 of the gate 7 into which the resin C is poured is 50% or more and 100% or less of the cross-sectional area E3 of the cavity 8, the flowability of the resin C is enhanced and the first lens portion 31a and the second lens The transferability of the periodic uneven structure in the portion 31 b can be enhanced. Therefore, the same effect as that of the first embodiment can be obtained.

As mentioned above, although the manufacturing method of the parts for optical communication concerning the embodiment and the parts for optical communication were explained, the manufacturing method of the parts for optical communication concerning this indication and the parts for optical communication are limited to each above-mentioned embodiment. And various modifications are possible. For example, although the mold 5 having the runners 6a and 6b, the gate 7, and the cavity 8 is described in the above embodiment, the configuration of the mold for manufacturing the optical communication component can be changed as appropriate.

Moreover, although the above-mentioned embodiment demonstrated the example in which the lens part 3 provided with the periodic uneven structure 3A was integrated with the lens component 1, the lens part provided with the periodic uneven structure is a different component from the lens part. It may be a lens member. In this case, relative alignment between the lens member and the optical waveguide can be performed with high accuracy as compared with the integrated lens component.

For example, as shown in FIG. 11, the lens member 41, which is a component separate from the lens component, is a communication lens, and has a periodic uneven structure similar to that of the periodic uneven structure 3A in the range X. In general, the accuracy of the position of the communication lens directly affects the light connection loss. For this reason, it is necessary to measure the position of the edge (periphery) of the lens with high accuracy using, for example, an optical microscope. However, when the periodic uneven structure is formed at the edge portion of the lens, the position measurement may be difficult because the edge portion may be unclear.

Therefore, in the example shown in FIG. 11, the beam diameter of light passing through the lens member 41 is V1, the diameter of the range X in which the periodic uneven structure of the lens member 41 is formed V2, the diameter of the lens member 41 V3, Then, the relationship of V1 <V2 <V3 is satisfied. By satisfying the relationship of V1 <V2, Fresnel reflection of light passing through the lens member 41 can be more effectively suppressed.

Further, by satisfying V2 <V3, the periodic uneven structure is not formed on the edge side of the range X, that is, there is a region without the periodic uneven structure in the outer peripheral portion, so the shape evaluation of the lens member 41 and the lens The position measurement of the member 41 can be performed easily and with high accuracy. A portion where the periodic uneven structure on the edge side of the range X is not formed is formed, for example, by applying a mask to the lens frame portion.

Moreover, although the above-mentioned embodiment demonstrated the lens component 1 provided with the several lens part 3, the number of lens parts may be one and can be changed suitably. Furthermore, although the optical connector 10 is provided with the refractive index matching layer 13, the refractive index matching layer can be omitted. In this case, the optical connector 10 in which the lens component 1, the optical fiber 11, and the optical fiber holding member 12 are integrated can be manufactured by the mold 5 in the same manner as the manufacturing method described above.

Furthermore, as for the lens member 41 which is a separate component from the lens part, although an example in which the periodic uneven structure is not formed in the outer peripheral part has been described, the lens part 3 is the outer periphery of the lens part 1 in which the lens part 3 is integrated. The part may have a region without a periodic uneven structure. Also in this case, the effect that the alignment between the optical fiber 11 and the lens component 1 can be performed with high accuracy can be obtained. As described above, the material, shape, size, number, and arrangement of each component of the optical communication component can be changed as appropriate, and the contents and order of each process in the method of manufacturing the optical communication component can be changed as appropriate. is there.

DESCRIPTION OF SYMBOLS 1 ... lens part, 2a ... end surface, 2b ... back end surface, 2c ... side surface, 2d ... top surface, 2e ... bottom surface, 2f ... recessed part, 2g ... gate mark, 3 ... lens part, 3A ... periodic uneven structure, 3a ... convex Part 4 guide hole (hole) 5 mold 6a, 6b runner 7 gate 8 cavity 8a lens frame portion 8b periodical uneven structure 8c pin 10 optical connector (Parts for optical communication) 11 Optical fiber 11a Tip surface 12 Optical fiber holding member 12a Optical fiber holding hole 12b Guide hole 12c Optical end face 12d Side surface 13, 26 Refraction Ratio matching layer 21 lens array 21a surface 21b recess 21c bottom surface 22 32 substrate 23 first optical waveguide 23a inclined surface 24 34 holding member 25 25th Optical waveguide, 31 ... lens module, Reference Signs List 1a: first lens portion, 31b: second lens portion, 31c: inclined surface, 31d: surface, 31e: recess, 31f: bottom surface, 33: light emitting / receiving element, 35: optical waveguide, 41: lens member, A, B ... area, C: resin, D1, D2, D3 ... direction, E1, E2, E3 ... sectional area, F1, F2, F3 ... sectional area, K1, K2 ... space, L1, L2, L3 ... light, P ... interval , R ... diameter, X ... range.

Claims (13)

1. A method of manufacturing a spatial coupling type optical communication component, comprising
   Injecting a resin from a gate into a cavity of a mold having a periodic uneven structure with a depth and a spacing of 100 nm or more and 1000 nm or less and having a lens frame portion with a diameter of 50 μm or more and 600 μm or less ,
   Curing the resin to form a lens component;
   Equipped with
   The ratio of the cross sectional area of the gate to the cross sectional area of the cavity is 50% or more and 100% or less.
   Method of manufacturing parts for optical communication.
2. The volume of the lens component is 9 mm ³ or more and 350 mm ³ or less,
   A method of manufacturing a component for optical communication according to claim 1.
3. Space-coupled optical communication components,
   Equipped with lens parts,
   The lens component has a lens portion with a diameter of 50 μm or more and 600 μm or less,
   The lens portion includes a periodic uneven structure having a height and a spacing of 100 nm or more and 1000 nm or less.
   The lens component has a hardened gate mark at a gate into which resin is poured, and a surface provided with the gate mark.
   The ratio of the area of the gate mark to the area of the surface is 50% or more and 100% or less.
   Parts for optical communication.
4. An optical fiber, an optical fiber holding member for holding the optical fiber, and an index matching layer for matching the refractive index,
   The optical fiber holding member has an optical fiber holding hole for holding the optical fiber, and a guide hole into which a guide pin for positioning is inserted.
   The optical fiber is fixed to the optical fiber holding member,
   The tip surface of the optical fiber is optically coupled to the lens portion through the refractive index matching layer,
   Positioning is performed by inserting the guide pin into the guide hole and a hole formed in the lens component,
   A component for optical communication according to claim 3.
5. The volume of the lens component is 9 mm ³ or more and 350 mm ³ or less,
   A component for optical communication according to claim 3 or 4.
6. The lens component has an abutment surface at a position closer to the end than the lens portion, and the guide hole is formed in the abutment surface.
   A component for optical communication according to claim 4.
7. The material of the lens component is the same as the material of the optical fiber holding member,
   A component for optical communication according to claim 4.
8. The thickness of the refractive index matching layer is 50 μm or less
   A component for optical communication according to claim 4.
9. The lens component comprises a plurality of the lens portions,
   A component for optical communication according to any one of claims 3 to 8.
10. The lens component has a region without the periodic uneven structure at an outer peripheral portion thereof.
    A component for optical communication according to any one of claims 3 to 9.
11. The optical communication component is an optical connector,
    A component for optical communication according to any one of claims 3 to 10.
12. The lens component is a lens array that optically couples an optical waveguide and an optical waveguide other than the optical waveguide.
    A component for optical communication according to claim 3.
13. The lens component is a lens module that optically couples an optical waveguide and a light emitting and receiving element.
    A component for optical communication according to claim 3.

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