Plastic ferrules for single-mode (SM) MU-type simplified receptacles are fabricated with a precise injection-molding technique using a liquid crystalline polymer (LCP). The fabricated plastic ferrules exhibit an eccentricity of < 0.6 µm and outer diameter variation of 1 µm. MU-type simplified plugs incorporating the plastic ferrules have an average insertion loss of 0.13 dB and a return loss of > 46 dB. The plastic ferrules exhibit good resistance in 500-cycle mating tests, and in vibration and impact tests as well. The initial optical characteristics are maintained during a temperature and humidity cycling test and a heat-cycling test.

A novel millimeter-wave slotted waveguide array antenna is developed for automotive radar systems. An antenna structure suitable for mass-production is proposed in this paper. The waveguide is composed of two parts; an upper plate and a bottom plate. It is not necessary to contact each other closely because they are divided at the center of the broad wall of the waveguide where the electric current is small. In addition, grating lobes are suppressed by using a cylindrical cavity around each slot and by controlling the slot arrangement without using dielectric material in the waveguide. We have fabricated the proposed antenna by metal injection molding. The measured antenna efficiency results in 55%, which is quite high in comparison with any other conventional low cost millimeter-wave antenna. This efficiency is almost the same as that of the antenna fabricated by precision metal machining. In this paper, it is confirmed that the proposed antenna could be manufactured with low cost.

We examined the creep properties and hazard rates of plastic ferrules to ensure the long-term reliablity of optical fiber connections. The endface deformation ΔL had to be smaller than 3 µm to keep the insertion-loss and return-loss fluctuation to acceptable levels in the worst case of random concatenation of similarly deformed plastic ferrules. From the fluctuation data, we estimated the time-to-failure tf at which the ΔL value became 3 µm. We estimated the acceleration parameters, median lifetimes ξ, and hazard rates λ by using tf values based on Weibull statistics. The ξ values decreased rapidly with increasing temperature and relative humidity. We found we could expect small λ values of < 0.1 FIT (FIT=10-9/hour) and of 1 FIT for 20 years in a normal atmosphere (25C/50%RH) and in a more severe case of 25C/90%RH, respectively.

We examined the creep properties and hazard rates of plastic split alignment sleeves to ensure the long-term reliablity of optical fiber connections. It required a gauge retention force Fr of more than 200 gf to suppress the fluctuation in the insertion loss of a plastic sleeve. From the fluctuation data, we estimated the time-to-failure tf at which the Fr value became 200 gf. We estimated the acceleration parameters, median lifetimes ξ, and hazard rates λ by using the tf values based on the Weibull statistics. The ξ values decreased rapidly with increasing temperature and relative humidity. Small λ values of < 0.01 FITs and of 1 FITs were expected for 20 years in a normal atmosphere (25C/50%RH) and in a more severe case of 25C/90%RH or 45C/50%RH.

We successfully fabricated split alignment sleeves for single-mode operation with the injection-molding technique using both thermosetting epoxy resin and thermoplastic polyetherimide (PEI) resin. The relationship between the surface smoothness and the connection-loss characteristics of these injection-molded plastic sleeves was investigated. We made two-dimensional contour maps of the outer and inner surfaces of the plastic sleeves using the measured surface roughness. There were many contour lines on both the outer and inner surfaces of the PEI sleeve. In contrast, the epoxy sleeves had very smooth surface profiles. An offset Δr was estimated by using the inner-surface roughness data of the sleeve-ferrule contact regions. The connection loss of the sleeve increased as the Δr value increased. The measured losses agree fairly well with the theoretical losses estimated by using the Δr values. The PEI sleeves exhibited large Δr values, and one-third of them had large connection losses of > 0.5 dB. In contrast, the epoxy sleeves had very small Δr values of < 0.6 µm, and exhibited an average loss of < 0.1 dB.

Millimeter-wave systems increasingly are entering into commercial systems, both for communication and sensors for traffic or industrial applications. In many cases, circuit technology of the involved front-ends includes monolithic and hybrid integrated circuits and even waveguide components like filters or antenna feeds. In addition to the standard technical and environmental requirements, these front-ends have to be fabricated in large quantities at very low cost. After a short review of the problems and some general interconnect and packaging techniques for mm-wave front-ends, achievements of a research program will be presented at the example of components for a 28 GHz communication front-end. Emphasis is put on a novel feed-through structure using multilayer carrier substrates for mm-wave circuits, some advances in electromagnetic field coupling for interconnects to mm-wave MMICs, and the realization of packages including waveguide components by plastic injection molding and electroplating. Results of filters and a diplexer produced in this way are shown, including pretuning of the filters to compensate the shrinking of the plastic parts during cooling.

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.

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).

The objective of this study is to realize a manipulator of 0.5 mm in outside diameter as a part of 'research and development of micro machine technology.' This manipulator is intended as a part of a working robot to fix or observe the inside wall of a small pipe. One of the important problems of this research is to establish a processing method of a tubular small structure. MIM, metal injection molding, has been adopted to fabricate such a small structure. As a processing method to machine small molds for MIM, finish processing with surface roughness of Rmax 0.1 µm has been under our research applying 'vibrational processing technology,' which was developed on our own. This paper presents the results of 'vibrational processing technology' surface finishing of molds for metal injection.