Patent ID: 9061473
Filing Date: 2015-06-23
Classification: B29C,B29D,B29K,G02B

Abstract:
1. A method of forming a single-mode polymer waveguide array assembly, the waveguide array assembly having a waveguide array and a plurality of ferrules attached to both ends of the assembly, the waveguide array having a plurality of cores and cladding surrounding the cores, and each of the plurality of cores being able to individually guide single-mode light from one ferrule to another ferrule, the method comprising the steps of: providing an initial process mold having a plurality of projecting portions or protruding portions prepared on an inner surface and corresponding to each of the plurality of cores in the waveguide array; applying an undercladding material to the inner surface of the initial process mold to cover the plurality of projecting portions; spin coating the applied undercladding material, the spin coating controlling a height of material and flattening a top surface of the material; applying ultraviolet (UV)-transparent cover film to the top surface of the flattened undercladding material; exposing the undercladding material to UV light via the applied cover film to UV-cure the undercladding material and bond the cover film to the undercladding material; removing the applied cover film and cured undercladding material together from the initial process mold; providing an intermediate process mold; positioning a plurality of ferrules at both ends of the intermediate process mold; bridging the intermediate process mold and the plurality of ferrules provided at both ends with the removed applied cover film and cured undercladding material, these being inserted toward a plurality of inner faces of the plurality of ferrules with the applied cover film side facing down; filling a plurality of trench or recessed portions of the cured undercladding material with a core material, the plurality of trench portions being formed by the plurality of projecting portions in the mold; spin coating the filled core material, the spin coating controlling a height of material and flattening a top surface of the material; exposing the core material to UV-light to cure the core material; applying an overcladding material to the cured core material and cured undercladding material; curing the applied overcladding material; and removing the intermediate process mold from the molded waveguide array.