Precise plastic V-grooved alignment parts for connecting single-mode optical fiber arrays to multi-port optical devices were successfully molded with a thermosetting resin by using a highly productive injection molding technique. The molded parts are two types of V-grooved blocks that are compatible with the size of optical devices having eight or twelve optical ports. Their dimensional accuracy must be better than 1 µm over the whole length of the V-grooves for efficient optical coupling. This strict requirement was satisfied using precisely processed molding tools with a specially chosen resin under optimum molding conditions. The feasibility of the optical alignment parts was assured by an evaluation of their loss characteristics and reliability in coupling single-mode fibers to 18 power splitters, where the average optical loss was 0.2 dB and the change in loss was less than 0.2 dB under a temperature cycling test and also under a damp heat test. These results show that plastic molded parts can be used for precise coupling of single-mode optical devices, and will lead to a breakthrough in innovation in the field of optical packaging.

Precise plastic V-grooved alignment parts for connecting single-mode optical fiber arrays to multi-port optical devices were successfully molded with a thermosetting resin by using a highly productive injection molding technique. The molded parts are two types of V-grooved blocks that are compatible with the size of optical devices having eight or twelve optical ports. Their dimensional accuracy must be better than 1 µm over the whole length of the V-grooves for efficient optical coupling. This strict requirement was satisfied using precisely processed molding tools with a specially chosen resin under optimum molding conditions. The feasibility of the optical alignment parts was assured by an evaluation of their loss characteristics and reliability in coupling single-mode fibers to 18 power splitters, where the average optical loss was 0.2 dB and the change in loss was less than 0.2 dB under a temperature cycling test and also under a damp heat test. These results show that plastic molded parts can be used for precise coupling of single-mode optical devices, and will lead to a breakthrough in innovation in the field of optical packaging.

Aiming at lower cost and further miniaturization, we developed a new optical coupling system for use as an optical interface of a parallel optical interconnect module, called ParaBIT-1. It consists of a new-structure 24-fiber bare fiber (BF) connector whose main parts are made of molded plastic and a 24-channel optical coupling component using new polymeric optical waveguide film. To prevent bare fibers from breaking, the BF connector plug has a fiber protector. This BF connector can be joined by direct physical contact between bare fibers in fiber guide holes with a 250-µm pitch. The buckling forces of the fibers themselves secure the physical contacts. The average measured insertion loss of the 24-fiber BF connector was 0.05 dB, and the return losses were over 35 dB. The optical coupling components are composed of a 24-ch polymeric optical waveguide film with 45 mirrors and the 24-fiber BF connector interface, and can be assembled by passive alignment. The high thermal stability of the film allows soldering, and the film is fabricated by direct photo patterning. The average insertion losses of the components for transmitter and receiver modules were 1.28 and 1.35 dB, respectively.