We successfully fabricated plastic ferrules and split alignment sleeves for single-mode fiber-optic connectors by the injection molding process. Liquid crystalline polymer (LCP) was used as the molding material for the ferrule. We introduced an eccentricity control mechanism into the ferrule mold and realized an eccentricity of less than 1 µm. As the molding material for the sleeve, thermosetting epoxy resin was used. Suitable mechanical properties were realized by employing appropriate dimensional design and the molding process. The optical characteristics of a system combining these plastic components are compatible with single-mode SC-type connectors and are also stable under hot and humid conditions.

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.

The static fatigue parameters of plastic sleeves are determined by dynamic fatigue and destructive tests. The failure probability and lifetime of the plastic sleeve are estimated by using these parameters. No failure is expected for 20 years if the plastic sleeve is used in a normal atmosphere (23, 60%RH) and hot water (50).