Method of manufacturing assembly of optical waveguide substrate and optical fiber aligning substrate

Abstract: In a method of forming an assembly of an optical waveguide substrate and an optical fiber aligning substrate by adjoining an end face of a main body of the optical waveguide substrate and an end face of a main body of the optical fiber aligning substrate, a starting block formed by a flat rectangular plate is divided along a dividing surface which intersects perpendicularly to a side wall as well as a bottom wall of the starting block which are selected as a reference surface to obtain the main bodies of the optical waveguide substrate and optical fiber aligning substrate, optical waveguides are formed on the main body of the optical waveguide substrate by using the side wall and bottom wall as a positional reference, V-shaped guide grooves are formed in the main body of the optical fiber aligning substrate by using the side wall and bottom wall as a positional reference, and optical fibers are inserted into the guide grooves. Then, the optical waveguide substrate and the optical fiber aligning substrate are coupled with each other by adjoining end faces thereof which have been formed by dividing the starting block such that the original side wall and bottom wall of the starting block are reconstructed. In this manner, end faces of the optical waveguides and end faces of the optical fibers can be aligned automatically in a precise and simple manner.

Description: The present invention relates to a method of manufacturing an assembly of an optical waveguide substrate comprising a main body and at least one optical waveguide formed in or on the main body and at least one optical fiber aligning substrate including a main body and at least one optical fiber held on the main body. Recently there has been proposed a technique for forming an optical waveguide substrate by inwardly diffusing titanium into a main body made of monocrystal of lithium niobate (LiNbO 3 ). Such an optical waveguide substrate may be utilized as a substrate for a waveguide type light modulator, a waveguide type branch and couple circuit and a waveguide type multiplexer and demultiplexer circuit. In the above mentioned optical waveguide substrate, it is necessary to couple an end face of an optical fiber with an end face of the light waveguide so that the light can be transmitted through the coupling with high efficiency. If there is a space between the end faces of these elements, or if the optical axes of their end faces are not aligned with each other, there may be a large loss in light transmission. So, these end faces have to be coupled with each other with high precision. There have been proposed various methods of coupling the end faces of these optical elements. In almost all methods, a laser light beam is transmitted through the optical elements and adjustment is performed such that an amount of transmitted laser light becomes maximum. However, this takes a very long time and the working efficiency is low, so that production efficiency is also low. JP-A-2-125209 addresses these drawbacks. In this known method, guide grooves are formed in one surface of the optical waveguide substrate and guide pins are provided on a connector for supporting the optical fibers, and when the optical fiber aligning substrate is coupled with the optical waveguide substrate, the guide pins are inserted into the guide grooves. The end face of the optical waveguide substrate is thus automatically aligned with the end face of the optical fiber aligning substrate. Upper and lower plates of the optical fiber holding connector are formed by silicon chips or plastic plates, so that it is very difficult to couple the end faces of the optical waveguides and optical fibres precisely, and hence difficult to obtain a high light coupling efficiency. JP-A-57/148715 describes a two-part connector module for optically connecting one set of optical fibre ends to another set. To make the connector module, longitudinal parallel surface grooves are formed in the surface of a plate, and a longitudinal hole drilled through the plate. The plate is then divided transversely, bisecting the hole and the grooves to form two connector parts, one to locate each set of fibre ends. With the fibre ends located in the grooves and the two parts juxtaposed, insertion of a common guide pin through both parts of the longitudinal hole effects alignment. We tried forming the optical waveguides in a substrate and inserting the optical fibers into V-shaped grooves formed in a surface of an optical fiber aligning substrate; after end faces of these substrates were precisely processed mechanically and polished optically they were coupled with each other, using contours of the substrates as reference surfaces. However, this process has a limitation in coupling precision between the end faces of the optical waveguide substrate and those of the optical fiber aligning substrate, and therefore a cumbersome adjustment of the optical axes is still required. The present invention has for its object to provide a novel and useful method of manufacturing an assembly of optical waveguide substrate and optical fiber aligning substrate, in which the end faces of these substrates can be coupled with each other precisely, so that the difficulty in adjusting the optical axes can be reduced. According to a first aspect we provide a method of making an assembly in which an optical waveguide carried by an optical waveguide substrate is in optical communication with an optical fibre carried by a fibre-alignment substrate, comprising (a) providing a starting block of substrate material having a working surface, and one or more other surfaces designated as reference surfaces; (b) dividing the starting block into an optical waveguide substrate and a fibre-alignment substrate by division at a dividing surface which intersects the working surface and the reference surface so that each of the substrates has a respective portion of each said surface and each has an end face formed by the division; (c) forming an optical waveguide in or on the working surface of the optical waveguide substrate extending to its end face, using a said reference surface portion thereof as a positional reference for positioning the waveguide on the substrate; (d) forming a guide groove in the working surface of the fibre-alignment substrate extending to its end face, using a said reference surface portion thereof as a positional reference for positioning the guide groove on the substrate, and inserting and fixing an optical fibre in the guide groove; (e) coupling the optical waveguide substrate and the fibre-alignment substrate by bringing their end faces together and reconstituting the reference surface to facilitate optical alignment of the optical fibre and optical waveguide. In a second aspect we provide a method of making an assembly in which an optical waveguide carried by an optical waveguide substrate is in optical communication with an optical fibre carried by a fibre-alignment substrate, comprising (a) providing a starting block of substrate material having a working surface, and one or more other surfaces designated as reference surfaces; (b) providing alignment marks narrower than the intended optical waveguide on the surface of the starting block; (c) dividing the starting block into an optical waveguide substrate and a fibre-alignment substrate by division at a dividing surface which intersects the working surface and the reference surface so that each of the substrates has a respective portion of each said surface, and which also intersects the alignment marks so that each of said substrates has respective alignment mark halves, as well as a respective end face formed by the division; (d) forming an optical waveguide in or on the working surface of the optical waveguide substrate extending to its end face, using a said alignment mark half thereof as a positional reference for positioning the waveguide on the substrate; (e) forming a guide groove in the working surface of the fibre-alignment substrate extending to its end face, using a said alignment mark half thereof as a positional reference for positioning the guide groove on the substrate, and inserting and fixing an optical fibre in the guide groove; (f) coupling the optical waveguide substrate and the fibre-alignment substrate by bringing their end faces together and reconstituting the reference surface to facilitate optical alignment of the optical fibre and optical waveguide. In a third aspect we provide a method of making an assembly in which an optical waveguide carried by an optical waveguide substrate is in optical communication with an optical fibre carried by a fibre-alignment substrate, comprising (a) providing a starting block of substrate material having a working surface, and one or more other surfaces designated as reference surfaces; (b) forming an optical waveguide or a forming pattern for an optical waveguide on the working surface of the starting block; (c) dividing the starting block into an optical waveguide substrate and a fibre-alignment substrate by division at a dividing surface which intersects the working surface and the reference surface so that each of the substrates has a respective portion of each said surface, and which also intersects the waveguide or forming pattern so that each of said substrates has a respective portion of the waveguide or forming pattern, as well as a respective end face formed by the division; (d) if only the forming pattern was formed before the division, completing formation of an optical waveguide on that portion of the forming pattern on the optical waveguide substrate; (e) forming a guide groove in the working surface of the fibre-alignment substrate extending to its end face, using the waveguide or forming pattern portion thereof as a positional reference for positioning the guide groove on the substrate, and inserting and fixing an optical fibre in the guide groove; (f) coupling the optical waveguide substrate and the fibre-alignment, substrate by bringing their end faces together and reconstituting the reference surface to facilitate optical alignment of the optical fibre and optical waveguide. In this method, the guide groove can be formed by using the optical waveguide as the positional reference, so that the formation of the guide groove can be carried out very precisely. For a better understanding of the invention, reference is taken to the accompanying drawings, in which: Figs. 1A and 1B are plan view and side view showing a starting block used in a first embodiment of the method; Figs. 2A and 2B are plan view and side view illustrating a step of dividing the starting block into an optical waveguide main body and two optical fiber aligning main bodies; Fig. 3 is a plan view of the main bodies, in which optical waveguides and V-shaped grooves have been formed; Fig. 4 is a plan view of the main bodies, showing optical fibers in the V-shaped grooves; Fig. 5 is a plan view depicting an assembly of the optical waveguide substrate and the optical fiber aligning substrate; Fig. 6 is a side view illustrating end faces of the optical waveguide substrate and the optical fiber aligning substrate; Fig. 7 is a plan view showing a starting block which is used in a second embodiment of the method; Fig. 8 is a plan view depicting a condition in which the starting block is cut into the main bodies of the optical waveguide substrate and optical fiber aligning substrates; Fig. 9 is a plan view illustrating assembly of the optical waveguide substrate and the optical fiber aligning substrate; Fig. 10 is a plan view of a starting block in which optical waveguides are formed; Fig. 11 is a plan view representing a condition in which the starting block is divided into main bodies of the optical waveguide substrate and optical fiber aligning substrates; Fig. 12 is a plan view of a starting block in which alignment marks and optical waveguides are formed; Fig. 13 is a plan view of the Fig. 12 starting block in which electrode films are formed on portions of the optical waveguides; Fig. 14 is a plan view depicting the starting block divided into main bodies of the optical waveguide substrate and optical fiber aligning substrates; Fig. 15 is a plan view of the main bodies of the optical fiber aligning substrate in which V-shaped grooves are formed; and Fig. 16 is a plan view showing the main bodies of the optical wave guide substrate and optical fiber aligning substrate coupled with each other. Figs. 1 to 6 show a first embodiment of the method according to the invention. In the following embodiments the present invention is applied to form an optical switching element of 4×4 columns, but it should be noted that the present invention may be applied to other optical elements. As shown in Figs. 1A and 1B, a starting block 1 is prepared. This starting block 1 may be formed by a monocrystal of lithium niobate or lithium tantalate (LiTaO 3 ), and may be cut out from a mother material. At least one of the outer surfaces is utilized as a reference surface. It should be noted that the reference surface is preferably formed by a flat surface. In the present embodiment, the starting block 1 is formed by a flat rectangular plate having six flat outer surfaces. The starting block 1 has a length of 50 mm, a width of 10 mm and a thickness of 1 mm. Next, the starting block 1 is divided along dividing lines or surfaces 2 to form a main body 3A of the optical waveguide substrate and two main bodies 3B and 3C of the optical fiber aligning substrate as illustrated in Figs. 2A and 2B. It should be noted that in the present embodiment, the division is performed such that the main bodies 3B and 3C situate on opposite sides of the main body 3A. The division may be carried out by, for instance a mechanical cutting using a dicing machine. The main body 3A has a length of 30 mm and the main bodies 3B and 3C have a length of 10 mm. Then, as depicted in Fig. 3, in a major surface of the main body 3A of the optical waveguide substrate there are formed four columns of optical waveguides 6. The optical waveguides 6 may be formed by a known method, such as the inward diffusion of titanium, outward diffusion of lithium and proton exchange method. The inward diffusion of titanium is preferred. When the optical waveguides 6 are formed by the inward diffusion of titanium, a titanium pattern is formed on the major surface of the main body 3A by well-known photolithography and the main body is then heated to diffuse titanium into the main body. In practice, during this diffusion, lithium is diffused from the main body 3A into the titanium pattern, so that the resulting optical waveguides 6 protude slightly from the surface of the main body. A depth of the optical waveguide is about 0-5 µm measured from the surface of the main body. It should be noted that the number of columns and the configuration of the optical waveguides 6 may be suitably selected in accordance with a final product. In this manner, an optical waveguide substrate 14 is formed. As shown in Fig. 3, on major surfaces of the main bodies 3B and 3C of the optical fiber aligning substrate there are formed four columns of V-shaped grooves 5 by a mechanical process. In the present embodiment, the V-shaped grooves 5 are formed such that an apex angle is about 70 degrees and a depth is about 109 µm. It should be noted that the number and positions of the V-shaped grooves 5 are selected in accordance with those of the optical waveguides 6 of the optical waveguide substrate 14. Further there are formed recesses 16 in communication with the V-shaped grooves 5. Then, optical fibers 7 having a diameter of 125 µm are inserted into the V-shaped grooves 6 of the main bodies 3B and 3C of the optical fiber aligning substrate as shown in Fig. 4 to form optical fiber aligning substrates 13A and 13B. In this case, end portions of the optical fiber cable coating 8 are inserted into the recesses 16. It should be noted that in the present embodiment, four optical fibers 7 are embedded in the same coating 8 in parallel with each other. A length of portions of the optical fibers 7 protruding from the coating 8 is about 5 mm. The optical fibers 7 are secured to the main bodies 3A and 3B by means of a suitable adhesive agent such as UV-cure adhesive agent. Then, the end faces 4 of the optical waveguide substrate 14 and the end faces 9 of the optical fiber aligning substrates 13A and 13B are polished optically. It should be noted that the optical polishing does not change the conformity of these end faces 9 and 19 which were obtained by cutting the same and single starting block 1. That is to say, the optical polishing is carried out to remove a very thin layer whose physical property has been affected by the mechanical process for cutting the starting block; the geometrical conformity of the end faces is not lost by the optical polishing. After that, the optical waveguide substrate 14 and optical fiber aligning substrates 13A, 13B are coupled with each other by adjoining the optically polished end faces 4 and 9 of these substrates as depicted in Fig. 5. This coupling may use a known adhesive agent. In the present embodiment, the substrates 14, 13A, 13B are coupled with each other by means of UV-cure adhesive agent. During the coupling, the optical waveguide substrate 14 and optical fiber aligning substrates 13A, 13B are aligned in mutually orthogonal three directions x, y and z. As shown in Fig. 5, the directions x and y are parallel to the plane of the drawing of Fig. 5 and the direction z is perpendicular to said plane. In the direction x, the alignment is carried out by coupling the substrates 14, 13A, 13B with each other without any space in between. The alignment in the directions y and z can be attained by utilizing the outer configuration of the substrates as will be explained hereinbelow. To this end, a suitable jig having L-shaped cross section may be utilized. In this case, the bottom walls of the substrates 14 and 13A, 13B are placed on an upper surface of a bottom portion of the jig and the side walls of the substrates are brought into contact with a surface of an upright portion of the jig. Upon preparing the starting block 1 shown in Figs. 1A and 1B, one of the side walls and a bottom wall are selected as a reference surface. When a side wall 11 illustrated in Fig. 1A is selected as the reference surface, after the starting block 1 has been divided into the three main bodies 3A, 3B and 3C, the optical waveguides 6 and V-shaped grooves 5 are formed using a side wall 11A of the main body 3A of the optical waveguide substrate, as well as side walls 11B, 11C of the main bodies 3B and 3C of the optical fiber aligning substrate, as a positional reference. It should be noted that these side walls 11A, 11B, 11C originated from the same side wall 11 of the starting block 1, so that the optical waveguides and V-shaped grooves can be formed precisely relative to each other. As illustrated in Fig. 6, the optical waveguides 6 and V-shaped grooves 5 are formed such that distances d1, d2, d3, d4 between the reference surface 11A and centre points of the optical waveguides 6 viewed in the direction y and distances d1, d2, d3, d4 between the reference surface 11B or 11C and centre points of the V-shaped grooves 5 are set to predetermined values. When the optical waveguide substrate 14 and the optical fiber aligning substrates 13A, 13B are coupled with each other, the side wall 11A of the substrate 14 and the side walls 11B, 11C of the optical fiber aligning substrates 13A, 13B are aligned with each other to reconstruct the original side wall 11 of the starting block 1. That is to say, the substrates 14, 13A and 13B are coupled with each other such that the side wall 11A of the optical waveguide substrate 14 and side walls 11B, 11C of the optical fiber aligning substrates 13A, 13B are aligned with each other in the direction y. Then, the end faces of the optical waveguides 6 which emerge at the end faces 4 of the substrate 14 and end faces of the optical fibers 7 which emerge in the end faces 9 of the substrates 13A, 13B are self-aligned in the direction y. When the bottom surface 10 of the starting block 1 shown in Fig. 1B is used as the reference surface, a bottom surface 10A of the main body 3A of the optical waveguide substrate and bottom surfaces 10B, 10C of the main bodies 3B, 3C of the optical fiber aligning substrate serve as the reference surfaces as depicted in Fig. 2B after the starting block 1 has been divided into the three main bodies. Then, the optical waveguides 6 and V-shaped grooves 5 are formed by using the bottom surfaces 10A, 10B and 10C as the positional reference. Finally the optical waveguide substrate 14 and optical fiber aligning substrates 13A and 13B are coupled with each other while the bottom surfaces 10A, 10B, 10C are aligned with each other to reconstruct the original bottom surface 10 of the starting block 1. In this manner, the end faces of the optical waveguides 6 and end faces of the optical fibers 7 inserted into the V-shaped grooves 5 are aligned in the direction z. That is to say, a centre point of each of the optical waveguides 6 substantially coincides with a centre point of each of the optical fibers 7 in the direction z. As taught herein, the substrates 13A, 13B and 14 are formed from the same and single starting block 1 and the coupling end faces 4 and 9 are obtained by dividing the starting block into the main bodies 3A, 3B, 3C. Therefore, the outer configurations of the substrates 13A, 13B, 14 and their coupling end faces 4, 9 are completely identical with each other, so that these substrates can be coupled with each other at an extremely high precision and thus the above mentioned alignments in the directions x, y and z can be attained very accurately. In the method in which the optical waveguide substrate and optical fiber aligning substrates are formed from different starting blocks, the outer configurations and coupling end faces of the substrates deviate from each other, and therefore it is practically impossible to obtain a precise alignment. As explained above, in the present embodiment, the optical fiber aligning substrates 13A, 13B can be accurately aligned with the optical waveguide substrate 14 in the directions x, y and z, and thus the end faces of the optical waveguides 6 can be precisely aligned with the end faces of the optical fibers 7 and there is no deviation in the optical axes of these optical elements. Particularly, since the coupling end faces 4, 9 of the optical waveguide substrate 14 and optical fiber aligning substrates 13A, 13B are obtained by dividing the starting block 1, there is no space or gap between these end faces, and the end faces of the optical waveguides 6 can be coupled with the end faces of the optical fibers 7 without any space in between. Therefore, loss of light due to reflection by the end faces can be decreased to a great extent. In this manner, according to the present method, it is no longer necessary to perform the adjustment of the optical axes between the end faces of the optical waveguides and the end faces of the optical fibers in order to suppress the loss in the light transmission, so that the working efficiency and productivity can be improved largely. When only one of the side wall 11 and bottom wall 10 of the starting block 1 is selected as the reference surface, it is preferable to select the side wall as the reference surface. In the present embodiment, the optical waveguides 6 are formed by the inward diffusion of titanium and it is rather difficult to increase the precision in the direction z. In such a case, it would be necessary to effect the optical axis adjustment in the direction z. When the starting block 1 is made of LiNbO 3 having a refractive index which is greatly different from that of the optical fiber, it is preferable to incline the end faces 4 of the optical waveguide substrate 14 and the end faces 9 of the optical fiber aligning substrates 13A, 13B by about 8 degrees with respect to a plane which is perpendicular to the side wall 11 in order to reduce the reflection between the end faces of the optical waveguides 6 and the end faces of the optical fibers 7. In the known method, the end faces of these substrates have to be processed precisely, but this process is very cumbersome and difficult. Further the the optical axes of the optical waveguides are liable to be inclined with respect to those of the optical fibers. In the method described herein, since the coupling end faces 4 and 9 of the substrates 14 and 13A, 13B are obtained by cutting the same and single starting block, it is no more necessary to carry out the above mentioned cumbersome and difficult processing of the end surfaces. Moreover, the inclination of the optical axes between the optical waveguides and the optical fibers can be avoided. Now a second embodiment of the method according to the invention will be explained. At first, a starting block 1 is prepared as shown in Figs. 1A and 1B. Then, there are formed alignment marks 12 at such positions that these alignment marks cross the division lines 2 as illustrated in Fig. 7. A width of the alignment marks 12 is set to be slightly smaller than a width of the optical waveguides. In the present embodiment, there are formed four alignment marks, but the number of the alignment marks may be selected at will. Further the alignment marks 12 may be formed by the mechanical process or photolithography. Next the starting block 1 is divided into the main bodies 3A, 3B and 3C as depicted in Fig. 8. During this division, the alignment marks 12 are also divided into alignment mark halves. That is to say, four alignment mark halves 12a remain on the main body 3A of the optical waveguide substrate and two alignment mark halves 12a remain on each of the two main bodies 3B, 3C of the optical fiber aligning substrates. Then the same processes as those of the first embodiment illustrated in Figs. 3 and 4 are conducted to obtain an assembly of the optical waveguide substrate 14 and the optical fiber aligning substrates 13A and 13B as shown in Fig. 9. In the present embodiment, the alignments in the directions x and z are effected in the same manner as that of the first embodiment, but the alignment in the direction y may be performed by using the alignment mark halves 12a and 12b. That is to say, the optical waveguides 6 are formed using the alignment mark halves 12b as a positional standard and the V-shaped grooves 5 are formed in the upper surfaces of the main bodies 3A, 3B using the alignment mark halves 12a as the positional reference. Then, the optical waveguide substrate 14 and optical fiber aligning substrates 13A, 13B are coupled with each other by using the side wall 11 as the positional reference in the direction y. In this manner, the alignment mark halves 12a and 12b are coupled with each other to reconstruct the original alignment marks 12. In the present embodiment, the alignment mark halves 12a and 12b are used as the positional reference for forming the optical waveguides 6 and V-shaped grooves 5, so that the alignment in the direction y can be performed further easily and positively. Next a third embodiment of the method according to the invention will be explained. At first, a starting block 1 is prepared as illustrated in Fig. 1. Optical waveguides 6 are formed in an upper surface of the starting block 1 as shown in Fig. 10 by means of the photolithography technique and heating process. Then, the starting block 1 is divided along the division lines 2 into one main body 3A of the optical waveguide substrate and two main bodies 3B, 3C of optical fiber aligning substrate as depicted in Fig. 11. In the present embodiment, on an upper surface of the main body 3A there are formed optical waveguides 6A, and at the same time on upper surfaces of the main bodies 3B and 3C of the optical fiber aligning substrate there are also formed optical waveguides 6B, 6C. Then, the upper surfaces of the main bodies 3B, 3C are processed to form V-shaped grooves for holding the optical fibers in position using their optical waveguides 6B, 6C as the positional reference. As stated above, the optical waveguides 6B, 6C protrude from the surfaces of the main bodies 3B, 3C, so that the V-shaped grooves can be formed along the optical waveguides by detecting the protrusions on the surface. In this manner, it is possible to form the V-shaped grooves in precise alignment with the optical waveguides 6B, 6C. Next the optical fibers are inserted into the V-shaped grooves and are secured thereto by an adhesive agent to form the optical fiber aligning substrates. Then the optical fiber aligning substrates are coupled with the optical waveguide substrate in the same manner as that of the previous embodiment and the end faces of the optical waveguides 6A are connected to the end faces of the optical fibers. In the present embodiment, the optical waveguides 6B, 6C are formed in the main bodies 3A and 3B of the optical fiber substrates and the V-shaped grooves are formed by using these optical waveguides as the positional reference, so that the V-shaped grooves can be formed very easily and precisely. In the present embodiment, after the optical waveguides have been formed, the starting block is divided. However it is also possible to divide the starting block after only a pattern for forming the optical waveguides has been formed. This pattern for forming the optical waveguides may be a photoresist pattern for etching the titanium film or a titanium pattern which is formed by etching the titanium film through the photoresist pattern. In the main bodies 3A, 3B of the optical fiber aligning substrate, the V-shaped grooves may be formed along such a pattern for forming the optical waveguides, while on the main body 3A of the optical waveguide substrate the optical waveguides are formed by effecting heat treatment. Figs. 12 and 13 are plan views showing processes in a fourth embodiment of the method according to the invention. Electrodes are provided on an upper surface of the optical waveguide substrate to construct optical modulators. As illustrated in Fig. 12, in the upper surface of the starting block 1 optical waveguides 6 and four alignment marks 12 are formed with the aid of photolithography. In this case, the four optical waveguides 6 are formed using the alignment marks 12 as a positional reference. Then, ten electrodes 15 are formed on predetermined portions of the optical waveguides 6 as depicted in Fig. 13. In this case, a mask for forming the electrodes 15 is positioned on the upper surface of the starting block 1, using the alignment marks 12 as positional reference so that the electrodes can be precisely positioned with respect to the optical waveguides 6. Next, as shown in Fig. 14, the starting block 1 is divided along cutting lines 2 to form the optical waveguide'substrate 14 having optical waveguides 6A formed therein and main bodies 3B, 3C of the optical fiber aligning substrate. It should be noted that the alignment marks 12 are divided into alignment mark halves 12a, 12b. Then, the upper surfaces of the main bodies 3B, 3C of the optical fiber aligning substrate are processed along the optical waveguides 6B, 6C to form V-shaped grooves 5 as shown in Fig. 15, while the alignment mark halves 12a are used as the positional reference. After the optical fibers 7 are inserted into the V-shaped grooves 5, the optical fiber aligning substrates 13A, 13B are coupled with the optical waveguide substrate 14 in the same manner as that explained in the previous embodiments to form an assembly of the optical waveguide substrate 14 and optical fiber aligning substrates 13A, 13B as depicted in Fig. 16. Also in the present embodiment, the advantages which could be obtained in the previous embodiments can be attained, and further since the optical waveguides 6A and the electrodes 15 are provided by using the alignment marks 12, the alignment of the optical waveguides and the electrodes can be performed precisely and easily. The present invention is not limited to the embodiments explained hereinbefore and many modifications and alternations may be conceived by those skilled in the art within the scope of the invention. For instance, in the second embodiment, the alignment marks 12 and optical waveguides 6 may be formed simultaneously by the photolithography as shown in Fig. 12. In the above embodiments, the optical waveguides are formed by the inward diffusion of titanium, but the present invention may be equally applied to a so-called glass optical waveguide (ion exchange glass optical waveguide, ion implanted optical waveguide). Further in the above embodiments, the optical waveguides are formed in the surface of the main body, but it is also possible to deposit an active layer on the main body by sputtering or epitaxial growth and the optical waveguides may be formed in this active layer. In such a case, the side wall of the starting block may be advantageously used as the positional reference. Adjustment of the optical axes in the direction z is then needed. Moreover, a protective cover plate may be provided on the optical fiber aligning substrate such that the optical fibers are clamped between the protective cover plate and the substrate. As explained above in detail, in the method according to the present invention, the optical waveguide substrate and optical fiber aligning substrates are formed from the same and single starting block and further these substrates are coupled with each other at end faces which were created by dividing the starting block, so that the original outer configuration of the starting block is reconstructed. Therefore, the optical waveguide substrate and optical fiber aligning substrates can be assembled in an easy and precise manner, so that the end faces of the optical waveguides and optical fibers can be aligned with each other very accurately without introducing undesired inclination of the optical axes. Therefore, the loss of light transmission due to the reflection and leakage of light at the coupling end faces may be reduced to a great extent. In this manner, the working efficiency and productivity of the assembly of the optical waveguide substrate and optical fiber aligning substrates may be improved.

Claims: A method of making an assembly in which an optical waveguide (6) carried by an optical waveguide substrate (3A) is in optical communication with an optical fibre (7) carried by a fibre-alignment substrate (38,C), comprising (a) providing a starting block (1) of substrate material having a working surface, and one or more other surfaces designated as reference surfaces (10,11); (b) dividing the starting block (1) into an optical waveguide substrate (3A) and a fibre-alignment substrate (3B,C) by division at a dividing surface (2) which intersects the working surface and the reference surface (10,11) so that each of the substrates (3A,B,C) has a respective portion (10A,B,C;11A,B,C) of each said surface and each has an end face (9,4) formed by the division; (c) forming an optical waveguide (6) in or on the working surface of the optical waveguide substrate (3A) extending to its end face (4), using a said reference surface portion (11A) thereof as a positional reference for positioning the waveguide (6) on the substrate (3A); (d) forming a guide groove (5) in the working surface of the fibre-alignment substrate (3B,C) extending to its end face (9), using a said reference surface portion (11B,C) thereof as a positional reference for positioning the guide groove (5) on the substrate (3B,C), and inserting and fixing an optical fibre (7) in the guide groove (5); (e) coupling the optical waveguide substrate (3A) and the fibre-alignment substrate (3B,C) by bringing their end faces (4,9) together and reconstituting the reference surface (10,11) to facilitate optical alignment of the optical fibre (7) and optical waveguide (6). A method of making an assembly in which an optical waveguide (6) carried by an optical waveguide substrate (3A) is in optical communication with an optical fibre (7) carried by a fibre-alignment substrate (3B,C), comprising (a) providing a starting block (1) of substrate material having a working surface, and one or more other surfaces designated as reference surfaces (10,11); (b) providing alignment marks (12) narrower than the intended optical waveguide (6) on the surface of the starting block (1); (c) dividing the starting block (1) into an optical waveguide substrate (3A) and a fibre-alignment substrate (38,C) by division at a dividing surface (2) which intersects the working surface and the reference surface (10,11) so that each of the substrates (3A,B,C) has a respective portion (10A,B,C;11A,B,c) of each said surface, and which also intersects the alignment marks (12) so that each of said substrates (3A,B,C) has respective alignment mark halves (12a,12b), as well as a respective end face (4,9) formed by the division; (d) forming an optical waveguide (6) in or on the working surface of the optical waveguide substrate (3A) extending to its end face (4), using a said alignment mark half (12b) thereof as a positional reference for positioning the waveguide (6) on the substrate (3A); (e) forming a guide groove (5) in the working surface of the fibre-alignment substrate (3B,C) extending to its end face (9), using a said alignment mark half (12a) thereof as a positional reference for positioning the guide groove (5) on the substrate (3B,C), and inserting and fixing an optical fibre (7) in the guide groove (5); (f) coupling the optical waveguide substrate (3A) and the fibre-alignment substrate (3B,C) by bringing their end faces (4,9) together and reconstituting the reference surface (10,11) to facilitate optical alignment of the optical fibre (7) and optical waveguide (6). A method of making an assembly in which an optical waveguide (6) carried by an optical waveguide substrate (3A) is in optical communication with an optical fibre (7) carried by a fibre-alignment substrate (3B,C), comprising (a) providing a starting block (1) of substrate material having a working surface, and one or more other surfaces designated as reference surfaces (10,11); (b) forming an optical waveguide (6) or a forming pattern for an optical waveguide on the working surface of the starting block (1); (c) dividing the starting block (1) into an optical waveguide substrate (3A) and a fibre-alignment substrate (3B,C) by division at a dividing surface (2) which intersects the working surface and the reference surface (10,11) so that each of the substrates (3A,B,C) has a respective portion (10A,B,C;11A,B,C) of each said surface, and which also intersects the waveguide (6) or forming pattern so that each of said substrates (3A,B,C) has a respective portion of the waveguide (6) or forming pattern, as well as a respective end face (4,9) formed by the division; (d) if only the forming pattern was formed before the division, completing formation of an optical waveguide (6) on that portion of the forming pattern on the optical waveguide substrate (3A); (e) forming a guide groove (5) in the working surface of the fibre-alignment substrate (3B,C) extending to its end face (9), using the waveguide or forming pattern portion thereof as a positional reference for positioning the guide groove (5) on the substrate (3B,C), and inserting and fixing an optical fibre (7) in the guide groove (5); (f) coupling the,optical waveguide substrate (3A) and the fibre-alignment substrate (3B,C) by bringing their end faces (4,9) together and reconstituting the reference surface (10,11) to facilitate optical alignment of the optical fibre (7) and optical waveguide (6). A method according to claim 3 in which before dividing the starting block (1) alignment marks (12) narrower than the optical waveguide (6) are formed on the surface of the starting block (1) crossing the dividing surface (2) so that they are divided into alignment mark halves (12a,12b) when the starting block (1) is divided and are used for positional references for forming the optical waveguide (6) and the groove (5). A method according to claim 2 or claim 4 in which when the optical waveguide substrate (3A) and the fibre-alignment substrate (3B,C) are coupled together the alignment mark halves (12a,12b) are combined to reconstruct the original alignment marks (12). A method according to claim 3 or claim 4 in which an optical waveguide forming pattern is made by providing a titanium film on the starting block (1) and forming a photoresist pattern on the titanium film, the photoresist pattern being identical in shape with the optical waveguide pattern to be formed. A method according to claim 6 in which the guide groove (5) is formed along that portion of the photoresist pattern which is on the fibre-alignment substrate (3B,C). A method according to claim 3 or claim 4 in which the optical waveguide (6) is formed by providing a titanium film on the starting block (1), selectively etching the titanium film by photolithography to form a titanium pattern and heating the optical waveguide substrate (3A) to diffuse titanium into the substrate and thereby form the waveguide (6). A method according to claim 8 in which the guide groove (5) is formed along that portion of the optical waveguide (6) on the fibre-alignment substrate (3B,C). A method according to any one of the preceding claims in which each reference surface is a flat outer surface of the starting block (1). A method according to any one of the preceding claims in which the starting block (1) is a flat rectangular plate having three orthogonal pairs of outer surfaces, the working surface on which the optical fibre (7) and waveguide (6) are provided being the top major surface, and at least a side surface (11) perpendicular to the dividing surface (2) being selected as a said reference surface. A method according to claim 10 in which the bottom surface (10) of the rectangular plate is also used as a reference surface. A method according to any one of the preceding claims in which the starting block (1) is divided at two dividing surfaces (2) to form an optical waveguide substrate (3A) and two fibre-alignment substrates (3B,C), one at each end of the optical waveguide substrate (3A).

Inventors: ABE TETSUHISA, HAMAJIMA AKIRA, ICHIGI TAKENORI, KONDO ATSUO, ABE, TETSUHISA, HAMAJIMA, AKIRA, ICHIGI, TAKENORI, KONDO, ATSUO
Applicants: NGK INSULATORS LTD, NGK INSULATORS, LTD.
Application year: 1992
Main classification: G02B6
IPC codes: G02B6