Patent ID: 9023256
Filing Date: 2015-05-05
Classification: B29C,B29D,B29K,G02B

Abstract:
1. A method of forming a single-mode polymer waveguide array connector, the waveguide array connector comprising a waveguide array and a plurality of ferrules attached to opposite ends of the waveguide array, the waveguide array comprising a plurality of cores and a cladding surrounding the cores, and each core being capable of independently guiding single-mode light entering from one ferrule to another ferrule, the method comprising: providing a first mold (A) having a plurality of ridges formed on a surface thereof, the plurality of ridges being intended to shape the plurality of cores of the waveguide array, wherein the first mold (A) is made of a transparent resin and is previously molded in a die; providing a second mold (B) that is to be combined with the first mold (A) and has a plurality of hollows formed in a surface thereof, the hollows corresponding to the plurality of ridges and being intended to shape the cladding portion surrounding the cores of the waveguide array, wherein the second mold (B) is separable into three parts, and the three parts are a first mold part (B providing a dry film to form the cladding between the first mold (A) and the second mold (B); pressing the dry film between the first mold (A) and the second mold (B) arranged with surfaces thereof facing each other; applying UV light to the dry film to harden the dry film; laminating a plurality of trench portions formed in the dry film with a dry film to form laminated core material, the plurality of trench portions being formed in conformity with shapes of the plurality of ridges; applying UV light to the laminated core material to harden the laminated core material; polishing an upper surface of the core material to provide an intermediate polymer waveguide array; applying an over-cladding material onto the core material and a hardened under-cladding material; hardening the over-cladding material; providing the plurality of ferrules so as to be positioned at opposite ends of the second mold (B); inserting the polymer waveguide array into interiors of the plurality of ferrules so as to bridge the second mold (B) and the plurality of ferrules provided at the opposite ends of the second mold (B); and removing the second mold part (B