Patent ID: 8512500
Filing Date: 2013-08-20
Classification: G02B

Abstract:
1. A method of manufacturing an optical waveguide using a flat die having a groove therein, the method comprising: (a) forming a first cladding sheet on a base substrate; (b) placing the first cladding sheet and the base substrate on the flat die such that the first cladding sheet faces the groove of the flat die and the groove of the flat die extends beyond side surfaces of the first cladding sheet; (c) filling the groove with a liquid resin by injecting the liquid resin from an end portion of the groove that extends beyond one of the side surfaces of the first cladding sheet and then curing the liquid resin while pressing the base substrate against the flat die via the first cladding sheet, thereby forming a mirror support on the first cladding sheet; (d) removing the flat die from the first cladding sheet; (e) forming a mask on the first cladding sheet to cover the first cladding sheet with the mirror support exposed and forming a metal reflection film on a surface of the mirror support; (f) forming a core sheet on the first cladding sheet such that the core sheet covers the mirror support that is formed with the metal reflection film; (g) patterning the core sheet to form a plurality of core portions, the plurality of core portions being spaced from each other and being perpendicular to the mirror support; (h) covering the core portions with a second cladding sheet; (i) removing the base substrate from the first cladding sheet, thereby producing an optical waveguide bundle that includes the first cladding sheet, the plurality of core portions, the mirror support and the second cladding sheet; and (j) cutting the optical waveguide bundle into individual optical waveguides each including a part of the mirror support and at least one of the core portions.