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JP3984136B2 - Optical fiber array and optical fiber array substrate - Google Patents
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JP3984136B2 - Optical fiber array and optical fiber array substrate - Google Patents

Optical fiber array and optical fiber array substrate Download PDF

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Publication number
JP3984136B2
JP3984136B2 JP2002278308A JP2002278308A JP3984136B2 JP 3984136 B2 JP3984136 B2 JP 3984136B2 JP 2002278308 A JP2002278308 A JP 2002278308A JP 2002278308 A JP2002278308 A JP 2002278308A JP 3984136 B2 JP3984136 B2 JP 3984136B2
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Prior art keywords
optical fiber
substrate
groove
gap
adhesive
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JP2002278308A
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JP2004117610A (en
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慎介 仁井山
之裕 横町
弘樹 板倉
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Sumitomo Riko Co Ltd
Sumitomo Electric Industries Ltd
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Sumitomo Electric Industries Ltd
Tokai Rubber Industries Ltd
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Priority to US10/670,136 priority patent/US6882790B2/en
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Description

【0001】
【発明の属する技術分野】
本発明は、複数の光ファイバを位置決めして接着剤により一体化する光ファイバアレイと、そのための光ファイバアレイ用基板に関する。
【0002】
【従来の技術】
光ファイバアレイは、複数本の光ファイバを所定のピッチで平行に位置決めして配列し、プレーナ型の光導波路(PLC)との接続又は多心光ファイバ同士を接続するのに用いられる。図1は一般的な光ファイバアレイの概略を示す図で、図1(A)は斜視図、図1(B)及び図1(C)はa1−a1の部分断面図である。図中、1は光ファイバアレイ、2は光ファイバ、2aはファイバ被覆部、3は基板、3aは溝形成部、3bは平坦部、4は蓋板、5は溝(V字状溝)、6は接着材、7,8は間隙、9は段差部を示す。
【0003】
図1(A)に示すように、光ファイバアレイ1は、基板3と蓋板4との間に複数の光ファイバ2を所定の配列ピッチTで平行一列に保持固定して構成される。
基板3は、溝形成部3aと平坦部3bとを段差部9で示すように段差をつけて形成され、溝形成部3aの上面には光ファイバ2を収納する複数の溝5が平行に形成されている。溝5は、図1(B)に示すように、一般的にはV字状に形成されていて、光ファイバ2はV字状の溝5の両側面と蓋板4の押さえ面の3点で位置決めされる。また、光ファイバ2の配列ピッチTを光ファイバ2の外径に近づけた高密度配列の光ファイバアレイの場合は、図1(C)に示すようになる。
【0004】
上記の光ファイバアレイ1を製造する場合、光ファイバ2の先端の被覆を除去してガラスの裸ファイバを露出させて基板3の溝5に収納配列し、上方から蓋板4で押さえて位置決めする。この後、基板3の溝形成部3aの先端側又は後端側から接着剤6を注入する。接着剤6は、光ファイバ2と基板3と蓋板4との間に生じる間隙7内、並びに光ファイバ2と溝5との間に生じる間隙8内に毛細管作用で浸入し、これらの間隙を埋めて、光ファイバ2と基板3と蓋板4とを接着一体化する。
【0005】
光ファイバ2は、露出されたガラスの裸ファイバをV字状の溝5に収納配列し、被覆が残るファイバ被覆部2aを基板3の平坦部3b上に載置する。光ファイバ2が蓋板4により押さえられ接着剤6で接着固定された後、ファイバ被覆部2aは平坦部3bに他の接着剤(図示せず)により接着固定される(例えば、特開2001−343547号公報参照)。
【0006】
【発明が解決しようとする課題】
以上のように構成される光ファイバアレイ1において、例えば、接着剤6を基板3の先端部側から付与し、毛細管作用で間隙7及び8内に充填したとする。接着剤6は、光ファイバ2と基板3の上面と蓋板4の下面との間に生じる間隙7と、光ファイバ2と基板3の溝5との間に生じる間隙8の2つの異なる間隙内に毛細管作用で浸入して充填される。上方の間隙7の横断面積S1が、下方の間隙8の横断面積S2より小さい場合、上方の間隙7内を毛細管作用で接着剤が浸入する速度は、下方の間隙8内を毛細管作用で接着剤が浸入する速度より速い。
【0007】
図2は、図1(B)のa2−a2断面を示し、基板3の先端側から接着剤6を付与した例を示す図である。図2(B)に示すように、上方の間隙7の横断面積S1が下方の間隙8の横断面積S2より小であるとすると、上述した接着剤6の浸入速度の違いにより、上方の間隙7内に浸入した接着剤6は、下方の間隙8内に浸入した接着剤6より、溝形成部3aの後端の出口側に早くに到達し、余分の接着剤が出口から流れ出て下方に垂れる。
【0008】
下方に垂れた接着剤は、下方の間隙8の出口側を塞ぐ形となる。下方の間隙8の出口側まで接着剤6が十分浸入していないうちに間隙8の出口を塞がれると、間隙8内に気泡Pが残る。間隙8内に気泡Pが残ると光ファイバ2と基板3との接着力が低下し、基板3が剥がれるやすくなる。また、間隙8内に気泡Pが残ると、温度変化により気泡Pが膨張変化し、光ファイバ2に曲げや側圧を与え、伝送損失を増加させる原因となる。
【0009】
本発明は、上述した事情に鑑みてなされたもので、接着剤を充填する間隙部分に気泡が生じない光ファイバアレイとそれに使用される光ファイバアレイ用基板の提供を課題とする。
【0010】
【課題を解決するための手段】
本発明による光ファイバアレイは、溝形成部と平坦部とを段差をつけて形成した基板と蓋板とからなり、基板の溝形成部に設けた両側壁が開き角度を持つ複数のV字状溝に、光ファイバを収納配列して蓋板で押さえて位置決めし、光ファイバと基板及び蓋板と間に生じる間隙部分に接着剤を充填して接着一体化する光ファイバアレイである。
そして、前記の基板の溝形成部の段差側で、前記のV字状溝の開き角度が徐々に広げるか、又は、V字状溝の深さが徐々に深くされ、溝頂部の高さが次第に低くされていて、光ファイバと基板の上面と蓋板の下面との間に生じる間隙部分の横断面積をS1とし、基板の溝と光ファイバとの間に生じる間隙部分の横断面積をS2としたとき、S1>S2としたものである。
【0011】
また、本発明による光ファイバアレイ用基板は、上記した光ファイバアレイを形成するためのものであって、複数の光ファイバを、基板の溝形成部に設けた両側壁が開き角度を持つV字状溝に収納配列して蓋板で押さえて位置決めし、光ファイバとの間に生じる間隙部分に接着剤を充填して接着一体化する光ファイバアレイ用基板である。なお、V字状溝の両側壁間の開き角度を70°を超え100°未満とするのが好ましい。
【0012】
【発明の実施の形態】
図1及び図2により、本発明の実施形態の概略を説明する。なお、図1及び図2は、従来技術の説明に用いた図であるが、形状自体は従来のものと同じであるので、本発明の基本形態の説明に援用する。
【0013】
本発明による光ファイバアレイ1は、図1(A)に示すように従来例で説明したのと同様に、基板3と蓋板4との間に複数の光ファイバ2を所定のピッチで平行一列に保持固定して構成される。基板3は、溝形成部3aと平坦部3bとを段差部9で示すように段差をつけた形状で形成され、溝形成部3aの上面には光ファイバ2を収納する複数の溝5が形成されている。光ファイバ2は、先端部分の被覆を除去されてガラスの裸ファイバを露出した状態とされ、溝形成部3aの溝5に収納配列され、被覆が除去されていないファイバ被覆部2aは平坦部3bに載置される。
【0014】
溝5は、図1(B)に示すように、例えば、V字状に形成されていて、溝5の両側壁は互いに平行でない開き角度θを有している。光ファイバ2が溝5内に収納されたとき、開き角度θを有する溝の両側壁と接する2点と、蓋板4の押さえ面で接する1点の合計3点で、光ファイバの位置決めが行なわれる。なお、蓋板4は光ファイバの位置決めができる程度で軽く押さえ、接着により一体化された後は、押さえ力は解放される。光ファイバ2が蓋板4により押さえられ接着剤6で接着固定された後、平坦部3bには他の接着剤(図示せず)が塗布され、ファイバ被覆部2aが接着固定される。
【0015】
光ファイバ2を接着する接着剤6には、例えば、硬化前の粘度が2.0Pa・s程度のエポキシ系紫外線硬化型の接着剤が用いられる。また、基板3と蓋板4には、光ファイバ2と熱膨張係数が近似するガラス(パイレックス(登録商標)ガラス、石英ガラス等)又はセラミック等が用いられ、溝加工は切削又はプレス成形で形成される。
【0016】
光ファイバ2を基板3の溝5にそれぞれ収納配列し、上から蓋板4で押さえて位置決めした後、接着剤6が基板3の溝形成部3aの先端側又は後部側から注入される。接着剤6は、図1(B)に示すように、光ファイバ2と基板3の上面と蓋板4の下面との間に生じる間隙7内、並びに光ファイバ2と溝5との間に生じる間隙8内に毛細管作用で浸入し、これらの間隙7,8を埋めて、光ファイバ2と基板3と蓋板4とを接着一体化する。
【0017】
本発明では、接着作業時に上方に位置する光ファイバ2と基板3の上面と蓋板4の下面との間に生じる間隙7の横断面積をS1とし、接着作業時に下方に位置する光ファイバ2と溝5との間に生じる間隙8の横断面積をS2としたとき、S1>S2となるように溝5の開き角度、基板3と蓋板4との間隔等を設定する。
【0018】
図2(A)に示すように、接着剤6を一方の側(図では左側)から間隙7,8内に同時に注入したとき、接着剤6は毛細管作用により同時に間隙7,8内を他方の出口側(図では溝形成部3aの後端部)に向かって浸入する。下方の間隙8の横断面積S2を、上方の間隙7の横断面積S1より小さくすることにより、接着剤6の浸入速度は、横断面積の小さい下方の間隙8の方が、上方の間隙7より速くなる。このため、下方の間隙8内が接着剤6で完全に満たされた後に、上方の間隙7が同様に接着剤6で満たされ、間隙8内に気泡が生じることはない。
【0019】
上述の図2(A)に対して、図2(B)は、解決すべき課題の項でも説明したように、下方の間隙8の横断面積S2が、上方の間隙7の横断面積S1より大きい場合である。この場合、接着剤6の浸入速度は、横断面積の大きい下方の間隙8の方が、上方の間隙7より遅くなる。このため、下方の間隙8内が接着剤6で完全に満たされないうちに、上方の間隙7が接着剤6で満たされ、間隙7の出口からあふれ出た余分の接着剤が下方に垂れて下方の間隙8の出口を塞ぎ、間隙8内に気泡Pが生じてしまう。
【0020】
上記した間隙7の横断面積S1と間隙8の横断面積S2との相対関係は、光ファイバ2の外径、ファイバの配列ピッチT、溝5の両側壁の開き角度θや形状によって変化する。光ファイバ2の外径は、通常の規格化された外径0.125mmのものを用いるとして一定とすれば、ファイバの配列ピッチTを大きくすれば、間隙7側の横断面積S1は比較的容易に大きくすることができる。また、溝5をV字状として両側壁の開き角度θを大きくすることにより間隙8側の横断面積S2は比較的容易に小さくすることができる。
【0021】
しかし、ファイバの配列ピッチTは、接続する相手側の光導波路の小形化、高集積化が進展していて、光ファイバ2のガラス外径にほぼ等しいピッチ(0.127mm)での形成が可能となっており、これに合わす必要がある。また、溝5の開き角度θをあまり大きくすると、光ファイバ2の位置決めが不安定となる。
【0022】
図3は、図1(C)に示すように、光ファイバ2のガラス外径を0.125mm、配列ピッチTを0.127mm、溝5をV字状とした高密度配列における、溝の開き角度θとS2/S1との関係を求めた図である。この図から、S2/S1<1とするには、V字状溝5の開き角度θは70°を超える角度にする必要がある。また、経験的にV字状溝5の開き角度θが100°以上になると、光ファイバ2が横ずれしたりして位置決めが不安定となる。したがって、位置決めという観点からは、S2/S1>0.3で、開き角度θを100°未満とする必要がある。なお、通常は上記のファイバ配列で、V字状溝5の開き角度θは60°程度に設定されている。
【0023】
図4は、溝5の断面形状の他の例を示す図である。基板3の溝5の断面形状を図1に示すようにV字状とするする代わりに、図4(A)に示すように、V字の谷部5bを平坦にした逆台形状とすることができる。ただし、平坦にした谷部5bは、光ファイバ2には接触しないものとする。この逆台形状溝は、V字状溝によるファイバの位置決め機能を損なわずに、光ファイバ2と溝5との間に生じる間隙8の横断面積S2を小さくすることができる。この結果、溝5の開き角度θをV字状溝の場合と同じとすれば、S2/S1をより小さくすることができる。また、S2/S1をV字状溝の場合と同じとすれば、開き角度θを更に小さくすることができる。
【0024】
また、基板3の溝5の断面形状を図1に示すようにV字状とするする代わりに、図4(B)に示すように、V字の谷部5bを円弧状にしたU字状とすることができる。ただし、円弧状にした谷部5bは、光ファイバ2には接触しないものとし、また、U字状溝の両側壁はV字状溝の場合と同様な開き角度を持っているものとする。このU字状溝は、V字状溝によるファイバの位置決め機能を損なわずに、光ファイバ2と溝5との間に生じる間隙8の横断面積S2を小さくすることができる。この結果、溝5の開き角度θをV字状溝又は逆台形状溝の場合と同じとすれば、S2/S1を更に小さくすることができる。また、S2/S1をV字状溝又は逆台形状溝の場合と同じとすれば、開き角度θを更に小さくすることができる。
【0025】
図5は、本発明による好ましい実施形態を説明する光ファイバアレイ用の基板を示す図で、図5(A)は基板の部分斜視図、図5(B)はV字状溝の開き角度の変化状態を示す図である。図中の符号は、図1及び図2で用いたのと同じ符号を用いることにより説明を省略する。図5は、基板3の溝形成部3aに形成されたV字状溝5の開き角度θを、溝形成部3aの後端の段差部9側で次第に大きくなるようにし、V字状溝5の谷部5bの深さ位置を溝形成部3aの上面から一定とした例である。
【0026】
光ファイバ2の配列ピッチTが小さく、図5のように頂部5aが先鋭形状となる場合は、V字状溝5の開き角度θが次第に大きくなるにしたがって、V字状溝5の頂部5aの高さが次第に低くなり、谷部5bとの差が小さい浅い形状のV字状溝となる。しかし、光ファイバ2の配列ピッチTが大きく、V字状溝5の頂部5aが平坦となる場合は、図5(A)の右端に示すV字状溝5の変化部5eで示すように、平坦な部分が次第に狭くなる形状となる。
【0027】
図5(A)に示すように、V字状溝5の開き角度θは、例えば、V字状溝5の長手方向中央部以降の位置から段差部9側に向けて、滑らかに次第に拡大させていくのが望ましい。なお、光ファイバ2の位置決めは、少なくともV字状溝5の長手方向の中央位置より前方の開き角度θが変化していない直線状部分で行なわれる。
【0028】
この開き角度θが変化していない直線状部分においては、図1で説明した間隙7の横断面積S1と間隙8の横断面積S2が、S1>S2となるようにV字状溝5の開き角度、基板3と蓋板4との間隔等が設定されているのが好ましい。また、光ファイバが図1(C)のような高密度の配列ピッチTで形成されている場合は、直線状部分におけるV字状溝5の両側壁間の開き角度は、70°を超え100°未満とするのが好ましい。
【0029】
図5(B)は、図5(A)のV字状溝5の長手方向のb−b,c−c,d−d位置における溝断面の変化状態を示した図である。b−b位置におけるV字状溝5の開き角度はθ1で、c−c位置ではθ2、d−d位置ではθ3で、θ1<θ2<θ3となる。長手方向の各位置におけるV字状溝5の谷部5bの深さ位置Hを溝形成部3aの上面ラインから一定とすると、頂部5aの高さが次第に低くなり、谷部5bとの差が小さい浅い形状のV字状溝となる。
【0030】
V字状溝5を以上のように形成することにより、溝形成部3aの段差部9側でV字状溝5と蓋板4との間の間隔が次第に拡大する。この結果、段差部9側の樹脂充填間隙の横断面積が増加し、接着剤が浸入しやすい形態となる。したがって、接着剤を段差部9側から基板の先端側に向けて毛細管作用により浸入させることにより、間隙内に気泡を生じさせることなくスムーズに間隙内に接着剤を充填することができる。また、段差部9が緩やかに変化するため、後部に付与される他の接着剤(図示せず)による応力集中を軽減し、損失増加を防止することができる。
【0031】
更に上記構成により、光ファイバ2は、溝形成部3aの段差部9側でV字状溝5の両側壁との接触から次第に離れ、後端部エッジ5cとは接触しない浮いた状態となる。この結果、溝形成部3aの段差部9で光ファイバ2に傷が付かず、断線の発生を防止することができる。
【0032】
図6は、図5に代わる他の実施形態を示す図で、図6(A)は基板の部分斜視図、図6(B)はV字状溝の深さの変化状態を示す図である。図中の符号は、図1及び図2で用いたのと同じ符号を用いることにより説明を省略する。図6は、基板3の溝形成部3aに形成されたV字状溝5の深さを、溝形成部3aの後端の段差部9側で次第に深くなるようにし、V字状溝5の開き角度θは一定とした例である。
【0033】
光ファイバ2の配列ピッチTが小さく、図6のように頂部5aが先鋭形状となる場合は、V字状溝5の谷部5bが次第に深くなるにしたがって、頂部5aの高さも次第に低くなり、頂部5aと谷部5bの相対高さは不変で、V字状溝5の横断面積もほぼ一定となる。しかし、光ファイバ2の配列ピッチTが大きく、V字状溝5の頂部5aが平坦となる場合は、図6(A)の右端に示すV字状溝5の変化部5eで示すように、平坦な部分が次第に狭くなる形状となる。
【0034】
図6(A)に示すように、V字状溝5の谷部5bは、例えば、V字状溝5の長手方向中央部以降の位置から段差部9側に向けて、滑らかに次第に深くさせていくのが望ましい。なお、光ファイバ2の位置決めは、少なくともV字状溝5の長手方向の中央位置より前方の谷部5bの深さが変化していない直線状の部分で行なわれる。
【0035】
この開き角度θが変化していない直線状部分においては、図1で説明した間隙7の横断面積S1と間隙8の横断面積S2が、S1>S2となるようにV字状溝5の開き角度、基板3と蓋板4との間隔等が設定されているのが好ましい。また、光ファイバが図1(C)のような高密度の配列ピッチTで形成されている場合は、直線状部分におけるV字状溝5の両側壁間の開き角度は、70°を超え100°未満とするのが好ましい。
【0036】
図6(B)は、図6(A)のV字状溝5の長手方向のb−b,c−c,d−d位置における溝の深さの変化状態を示した図である。b−b位置におけるV字状溝5の谷部5bの深さは、溝形成部3aの上面ラインからb−b位置ではH1、c−c位置ではH2、d−d位置ではH3で、H1<H2<H3となる。
【0037】
V字状溝5を以上のように形成することにより、図5の例の場合と同様に、溝形成部3aの段差部9側でV字状溝5と蓋板4との間の間隙が次第に拡大する。この結果、段差部9側の樹脂充填間隙の横断面積が増加し、接着剤が浸入しやすい形態となる。したがって、接着剤を段差部9側から基板の先端側に向けて毛細管作用により浸入させることにより、間隙内に気泡を生じさせることなくスムーズに接着剤を充填することができる。また、段差部9が緩やかに変化するため、後部に付与される他の接着剤(図示せず)に対する応力集中を軽減し、損失増加を防止することができる。
【0038】
更に上記構成により、図5の例と同様に光ファイバ2は、溝形成部3aの段差部9側でV字状溝5の両側壁との接触から次第に離れ、後端部エッジ5cとは接触しない浮いた状態となる。この結果、溝形成部3aの段差部9で光ファイバ2に傷が付かず、断線の発生を防止することができる。
【0039】
上述した、本発明による光ファイバアレイに用いる基板の形成は、上下金型を用いたプレス成形で形成するのが好ましい。V字状溝が長手方向で直線状の均一な形状でないことから、研削による機械加工は高度の制御と精密作業となり、生産性がよくない。しかし、プレス成形の場合は、金型を一旦作製すればよいので、金型のコストは多少増加するが、生産性の問題は生じない。また、プレス成形で形成されたV字状溝は、研削加工したものと比べて表面粗さが均一で滑らかなため、間隙内への接着剤の流れ性もよく、信頼性の高い光ファイバアレイ用基板及び光ファイバアレイを製造することができる。
【0040】
【発明の効果】
以上の説明から明らかなように、本発明によれば、光ファイバと基板の溝との間に生じる間隙部分に、気泡の発生を生じさせない状態で接着剤を充填することができ、基板の剥がれを防止すると共に、損失の増加を防止することができる。また、溝形成部の段部側の間隙を拡大することにより、応力集中と断線を防止することができる。
【図面の簡単な説明】
【図1】 本発明による光ファイバアレイの概略を説明する図である。
【図2】 基板の先端側から接着剤を付与したときの接着剤の流れを説明する図である。
【図3】 基板のV字状溝の開き角度と間隙の横断面積の関係を説明する図である。
【図4】 基板の溝形状の他の例を示す図である。
【図5】 本発明による基板のV字状溝の形状を示す図である。
【図6】 本発明による基板のV字状溝の他の形状を示す図である。
【符号の説明】
1…光ファイバアレイ、2…光ファイバ、2a…ファイバ被覆部、3…基板、3a…溝形成部、3b…平坦部、4…蓋板、5…溝(V字状溝)、5a…頂部、5b…谷部、5c…後端部エッジ、5e…変化部、6…接着剤、7,8…間隙、9…段差部。
[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an optical fiber array in which a plurality of optical fibers are positioned and integrated with an adhesive, and an optical fiber array substrate therefor.
[0002]
[Prior art]
The optical fiber array is used to connect a plurality of optical fibers to a planar optical waveguide (PLC) or to connect multi-core optical fibers by aligning and arranging a plurality of optical fibers in parallel at a predetermined pitch. FIG. 1 is a diagram showing an outline of a general optical fiber array. FIG. 1 (A) is a perspective view, and FIGS. 1 (B) and 1 (C) are partial sectional views of a1-a1. In the figure, 1 is an optical fiber array, 2 is an optical fiber, 2a is a fiber coating part, 3 is a substrate, 3a is a groove forming part, 3b is a flat part, 4 is a cover plate, 5 is a groove (V-shaped groove), 6 is an adhesive, 7 and 8 are gaps, and 9 is a stepped portion.
[0003]
As shown in FIG. 1A, the optical fiber array 1 is configured by holding and fixing a plurality of optical fibers 2 between a substrate 3 and a cover plate 4 in a parallel array at a predetermined arrangement pitch T.
The substrate 3 is formed such that the groove forming portion 3a and the flat portion 3b are stepped as shown by the step portion 9, and a plurality of grooves 5 for accommodating the optical fibers 2 are formed in parallel on the upper surface of the groove forming portion 3a. Has been. As shown in FIG. 1B, the groove 5 is generally formed in a V shape, and the optical fiber 2 has three points on both sides of the V-shaped groove 5 and the pressing surface of the cover plate 4. Positioned with. Further, in the case of an optical fiber array having a high density arrangement in which the arrangement pitch T of the optical fibers 2 is close to the outer diameter of the optical fiber 2, the optical fiber array is as shown in FIG.
[0004]
When the optical fiber array 1 is manufactured, the coating at the tip of the optical fiber 2 is removed to expose the bare glass fiber, and the optical fiber array 1 is accommodated in the groove 5 of the substrate 3 and is pressed and positioned by the lid plate 4 from above. . Thereafter, the adhesive 6 is injected from the front end side or the rear end side of the groove forming portion 3 a of the substrate 3. The adhesive 6 penetrates into the gap 7 generated between the optical fiber 2, the substrate 3, and the cover plate 4 and into the gap 8 generated between the optical fiber 2 and the groove 5 by capillary action. The optical fiber 2, the substrate 3, and the cover plate 4 are bonded and integrated.
[0005]
In the optical fiber 2, the exposed bare glass fiber is accommodated in the V-shaped groove 5, and the fiber coating portion 2 a on which the coating remains is placed on the flat portion 3 b of the substrate 3. After the optical fiber 2 is pressed by the cover plate 4 and bonded and fixed with the adhesive 6, the fiber coating portion 2a is bonded and fixed to the flat portion 3b with another adhesive (not shown) (for example, JP-A-2001-2001). 343547).
[0006]
[Problems to be solved by the invention]
In the optical fiber array 1 configured as described above, for example, it is assumed that the adhesive 6 is applied from the distal end side of the substrate 3 and is filled in the gaps 7 and 8 by capillary action. The adhesive 6 is used in two different gaps: a gap 7 generated between the optical fiber 2 and the upper surface of the substrate 3 and the lower surface of the cover plate 4, and a gap 8 generated between the optical fiber 2 and the groove 5 of the substrate 3. Infiltrated by capillary action. When the cross-sectional area S1 of the upper gap 7 is smaller than the cross-sectional area S2 of the lower gap 8, the speed at which the adhesive infiltrates in the upper gap 7 by capillary action is the adhesive in the lower gap 8 by capillary action. Is faster than the rate of penetration.
[0007]
FIG. 2 is a view showing an a2-a2 cross section of FIG. 1 (B) and showing an example in which the adhesive 6 is applied from the front end side of the substrate 3. As shown in FIG. 2B, if the cross-sectional area S1 of the upper gap 7 is smaller than the cross-sectional area S2 of the lower gap 8, the upper gap 7 is caused by the difference in the penetration speed of the adhesive 6 described above. The adhesive 6 that has entered inside reaches the outlet side at the rear end of the groove forming portion 3a earlier than the adhesive 6 that has entered the lower gap 8, and excess adhesive flows out from the outlet and hangs downward. .
[0008]
The adhesive hanging downwards closes the outlet side of the lower gap 8. If the outlet of the gap 8 is blocked before the adhesive 6 has sufficiently penetrated to the outlet side of the lower gap 8, bubbles P remain in the gap 8. If bubbles P remain in the gap 8, the adhesive force between the optical fiber 2 and the substrate 3 is reduced, and the substrate 3 is easily peeled off. Further, if the bubbles P remain in the gap 8, the bubbles P expand and change due to a temperature change, which causes bending or lateral pressure to the optical fiber 2 and increases transmission loss.
[0009]
The present invention has been made in view of the above-described circumstances, and an object thereof is to provide an optical fiber array in which bubbles are not generated in a gap portion filled with an adhesive and an optical fiber array substrate used therefor.
[0010]
[Means for Solving the Problems]
An optical fiber array according to the present invention comprises a substrate and a cover plate formed with a step between a groove forming portion and a flat portion, and a plurality of V-shaped openings whose side walls provided on the groove forming portion of the substrate have an opening angle. In this optical fiber array, optical fibers are accommodated and arranged in grooves, pressed by a cover plate and positioned, and a gap formed between the optical fiber, the substrate, and the cover plate is filled with an adhesive to be bonded and integrated.
Then, on the step side of the groove forming portion of the substrate, the opening angle of the V-shaped groove is gradually widened, or the depth of the V-shaped groove is gradually increased, and the height of the groove top portion is increased. The cross-sectional area of the gap portion that is gradually lowered and formed between the optical fiber and the upper surface of the substrate and the lower surface of the cover plate is S1, and the cross-sectional area of the gap portion that is formed between the groove of the substrate and the optical fiber is S2. In this case, S1> S2.
[0011]
A substrate for an optical fiber array according to the present invention is for forming the above-described optical fiber array, and a plurality of optical fibers are formed in a V-shape with both side walls provided at groove forming portions of the substrate having an opening angle. houses arranged Jo groove positioned presses with cover plate, Ru substrate der for an optical fiber array that integrally bonded by filling the adhesive in the gap portion generated between the optical fiber. The opening angle between both side walls of the V-shaped groove is preferably more than 70 ° and less than 100 ° .
[0012]
DETAILED DESCRIPTION OF THE INVENTION
The outline of the embodiment of the present invention will be described with reference to FIGS. 1 and 2. 1 and 2 are diagrams used for explaining the prior art, but since the shape itself is the same as the conventional one, it is used for explanation of the basic form of the present invention.
[0013]
As shown in FIG. 1A, an optical fiber array 1 according to the present invention has a plurality of optical fibers 2 arranged in parallel at a predetermined pitch between a substrate 3 and a cover plate 4 as described in the prior art. It is configured to be held and fixed to. The substrate 3 is formed in a shape in which the groove forming portion 3a and the flat portion 3b are stepped as shown by the step portion 9, and a plurality of grooves 5 for accommodating the optical fibers 2 are formed on the upper surface of the groove forming portion 3a. Has been. The optical fiber 2 is in a state in which the coating of the tip portion is removed to expose the bare glass fiber, and the optical fiber 2 is accommodated and arranged in the groove 5 of the groove forming portion 3a. Placed on.
[0014]
As shown in FIG. 1B, the groove 5 is formed in a V shape, for example, and both side walls of the groove 5 have an opening angle θ that is not parallel to each other. When the optical fiber 2 is stored in the groove 5, the optical fiber is positioned at a total of three points: two points in contact with both side walls of the groove having the opening angle θ and one point in contact with the pressing surface of the cover plate 4. It is. The cover plate 4 is lightly pressed to such an extent that the optical fiber can be positioned, and after being integrated by bonding, the pressing force is released. After the optical fiber 2 is pressed by the cover plate 4 and bonded and fixed with the adhesive 6, another adhesive (not shown) is applied to the flat portion 3b, and the fiber covering portion 2a is bonded and fixed.
[0015]
For the adhesive 6 that bonds the optical fiber 2, for example, an epoxy ultraviolet curing adhesive having a viscosity before curing of about 2.0 Pa · s is used. The substrate 3 and the cover plate 4 are made of glass (pyrex (registered trademark) glass, quartz glass, etc.) having a thermal expansion coefficient close to that of the optical fiber 2 or ceramic, and the grooving is formed by cutting or press molding. Is done.
[0016]
The optical fibers 2 are respectively housed and arranged in the grooves 5 of the substrate 3 and are positioned by being pressed by the cover plate 4 from above, and then the adhesive 6 is injected from the front end side or the rear side of the groove forming portion 3 a of the substrate 3. As shown in FIG. 1B, the adhesive 6 is generated in the gap 7 formed between the optical fiber 2 and the upper surface of the substrate 3 and the lower surface of the cover plate 4 and between the optical fiber 2 and the groove 5. The optical fiber 2, the substrate 3, and the cover plate 4 are bonded and integrated by filling the gap 8 by capillary action, filling the gaps 7 and 8.
[0017]
In the present invention, the cross-sectional area of the gap 7 formed between the optical fiber 2 positioned above during the bonding operation and the upper surface of the substrate 3 and the lower surface of the cover plate 4 is S1, and the optical fiber 2 positioned below during the bonding operation When the cross-sectional area of the gap 8 generated between the groove 5 is S2, the opening angle of the groove 5 and the distance between the substrate 3 and the cover plate 4 are set so that S1> S2.
[0018]
As shown in FIG. 2 (A), when the adhesive 6 is simultaneously injected into the gaps 7 and 8 from one side (left side in the figure), the adhesive 6 simultaneously passes through the gaps 7 and 8 by the capillary action. It enters toward the outlet side (the rear end portion of the groove forming portion 3a in the figure). By making the cross-sectional area S2 of the lower gap 8 smaller than the cross-sectional area S1 of the upper gap 7, the infiltration speed of the adhesive 6 is faster in the lower gap 8 having a smaller cross-sectional area than in the upper gap 7. Become. For this reason, after the lower gap 8 is completely filled with the adhesive 6, the upper gap 7 is similarly filled with the adhesive 6, and bubbles are not generated in the gap 8.
[0019]
2B, in FIG. 2B, the cross sectional area S2 of the lower gap 8 is larger than the cross sectional area S1 of the upper gap 7 as described in the section of the problem to be solved. Is the case. In this case, the penetration speed of the adhesive 6 is slower in the lower gap 8 having a larger cross-sectional area than in the upper gap 7. For this reason, before the inside of the lower gap 8 is completely filled with the adhesive 6, the upper gap 7 is filled with the adhesive 6, and the excess adhesive overflowing from the outlet of the gap 7 hangs downward and falls downward. The outlet of the gap 8 is blocked, and bubbles P are generated in the gap 8.
[0020]
The relative relationship between the cross-sectional area S1 of the gap 7 and the cross-sectional area S2 of the gap 8 varies depending on the outer diameter of the optical fiber 2, the arrangement pitch T of the fibers, the opening angle θ of both side walls of the groove 5, and the shape. If the outer diameter of the optical fiber 2 is constant assuming that a standardized outer diameter of 0.125 mm is used, the cross-sectional area S1 on the gap 7 side is relatively easy if the fiber arrangement pitch T is increased. Can be large. Further, by making the groove 5 V-shaped and increasing the opening angle θ of both side walls, the cross-sectional area S2 on the gap 8 side can be relatively easily reduced.
[0021]
However, the fiber arrangement pitch T is becoming smaller and more highly integrated, and can be formed at a pitch (0.127 mm) substantially equal to the glass outer diameter of the optical fiber 2. It is necessary to match this. If the opening angle θ of the groove 5 is too large, the positioning of the optical fiber 2 becomes unstable.
[0022]
As shown in FIG. 1 (C), the opening of the grooves in the high density array in which the optical fiber 2 has a glass outer diameter of 0.125 mm, the array pitch T is 0.127 mm, and the grooves 5 are V-shaped. It is the figure which calculated | required the relationship between angle (theta) and S2 / S1. From this figure, in order to satisfy S2 / S1 <1, the opening angle θ of the V-shaped groove 5 needs to exceed 70 °. Further, if the opening angle θ of the V-shaped groove 5 is empirically set to 100 ° or more, the optical fiber 2 is laterally displaced and the positioning becomes unstable. Therefore, from the viewpoint of positioning, it is necessary that S2 / S1> 0.3 and the opening angle θ be less than 100 °. Usually, in the above fiber arrangement, the opening angle θ of the V-shaped groove 5 is set to about 60 °.
[0023]
FIG. 4 is a diagram illustrating another example of the cross-sectional shape of the groove 5. Instead of making the cross-sectional shape of the groove 5 of the substrate 3 V-shaped as shown in FIG. 1, as shown in FIG. 4A, the V-shaped valley portion 5b is made into an inverted trapezoidal shape. Can do. However, it is assumed that the flat valley portion 5 b does not contact the optical fiber 2. This inverted trapezoidal groove can reduce the cross-sectional area S2 of the gap 8 formed between the optical fiber 2 and the groove 5 without impairing the fiber positioning function of the V-shaped groove. As a result, if the opening angle θ of the groove 5 is the same as that of the V-shaped groove, S2 / S1 can be further reduced. If S2 / S1 is the same as that of the V-shaped groove, the opening angle θ can be further reduced.
[0024]
Further, instead of making the cross-sectional shape of the groove 5 of the substrate 3 V-shaped as shown in FIG. 1, as shown in FIG. 4B, a U-shape having an arcuate V-shaped valley 5b. It can be. However, it is assumed that the arcuate valley portion 5b does not contact the optical fiber 2, and both side walls of the U-shaped groove have the same opening angle as that of the V-shaped groove. This U-shaped groove can reduce the cross-sectional area S2 of the gap 8 formed between the optical fiber 2 and the groove 5 without impairing the fiber positioning function of the V-shaped groove. As a result, if the opening angle θ of the groove 5 is the same as that of the V-shaped groove or the inverted trapezoidal groove, S2 / S1 can be further reduced. Further, if S2 / S1 is the same as that of the V-shaped groove or the inverted trapezoidal groove, the opening angle θ can be further reduced.
[0025]
5A and 5B are diagrams showing a substrate for an optical fiber array illustrating a preferred embodiment according to the present invention . FIG. 5A is a partial perspective view of the substrate, and FIG. 5B is an opening angle of a V-shaped groove. It is a figure which shows a change state. The reference numerals in the figure are the same as those used in FIG. 1 and FIG. FIG. 5 shows that the opening angle θ of the V-shaped groove 5 formed in the groove forming portion 3a of the substrate 3 is gradually increased on the stepped portion 9 side at the rear end of the groove forming portion 3a. This is an example in which the depth position of the valley portion 5b is constant from the upper surface of the groove forming portion 3a.
[0026]
When the arrangement pitch T of the optical fibers 2 is small and the top 5a has a sharp shape as shown in FIG. 5, as the opening angle θ of the V-shaped groove 5 gradually increases, the top 5a of the V-shaped groove 5 increases. The height gradually decreases, and a shallow V-shaped groove with a small difference from the valley 5b is obtained. However, when the arrangement pitch T of the optical fibers 2 is large and the top part 5a of the V-shaped groove 5 is flat, as shown by the change part 5e of the V-shaped groove 5 shown at the right end of FIG. The flat portion is gradually narrowed.
[0027]
As shown in FIG. 5A, the opening angle θ of the V-shaped groove 5 is, for example, gradually and gradually enlarged from the position after the longitudinal center of the V-shaped groove 5 toward the stepped portion 9 side. It is desirable to go. The optical fiber 2 is positioned at a linear portion where the opening angle θ ahead of the center position in the longitudinal direction of the V-shaped groove 5 is not changed.
[0028]
In the linear portion where the opening angle θ does not change, the opening angle of the V-shaped groove 5 is such that the cross-sectional area S1 of the gap 7 and the cross-sectional area S2 of the gap 8 described in FIG. The distance between the substrate 3 and the cover plate 4 is preferably set. When the optical fiber is formed with a high-density array pitch T as shown in FIG. 1C, the opening angle between both side walls of the V-shaped groove 5 in the linear portion exceeds 70 ° and is 100. It is preferable to be less than °.
[0029]
FIG. 5B is a diagram showing a change state of the groove cross section at the positions bb, cc, and dd in the longitudinal direction of the V-shaped groove 5 of FIG. The opening angle of the V-shaped groove 5 at the bb position is θ1, θ2 at the cc position, θ3 at the dd position, and θ1 <θ2 <θ3. If the depth position H of the valley portion 5b of the V-shaped groove 5 at each position in the longitudinal direction is constant from the upper surface line of the groove forming portion 3a, the height of the top portion 5a gradually decreases, and the difference from the valley portion 5b is It becomes a small shallow V-shaped groove.
[0030]
By forming the V-shaped groove 5 as described above, the gap between the V-shaped groove 5 and the cover plate 4 gradually increases on the stepped portion 9 side of the groove forming portion 3a. As a result, the cross-sectional area of the resin filling gap on the side of the stepped portion 9 is increased, and the adhesive can easily enter. Therefore, by allowing the adhesive to enter from the stepped portion 9 side toward the tip side of the substrate by capillary action, the adhesive can be smoothly filled in the gap without generating bubbles in the gap. Further, since the step portion 9 changes gently, stress concentration due to another adhesive (not shown) applied to the rear portion can be reduced, and an increase in loss can be prevented.
[0031]
Further, with the above configuration, the optical fiber 2 is gradually separated from contact with both side walls of the V-shaped groove 5 on the stepped portion 9 side of the groove forming portion 3a, and is in a floating state where it does not come into contact with the rear end edge 5c. As a result, the optical fiber 2 is not damaged at the step portion 9 of the groove forming portion 3a, and the occurrence of disconnection can be prevented.
[0032]
6A and 6B are diagrams showing another embodiment instead of FIG. 5, FIG. 6A is a partial perspective view of the substrate, and FIG. 6B is a diagram showing a change state of the depth of the V-shaped groove. . The reference numerals in the figure are the same as those used in FIG. 1 and FIG. In FIG. 6, the depth of the V-shaped groove 5 formed in the groove forming portion 3a of the substrate 3 is gradually increased on the stepped portion 9 side at the rear end of the groove forming portion 3a. In this example, the opening angle θ is constant.
[0033]
When the arrangement pitch T of the optical fibers 2 is small and the top 5a has a sharp shape as shown in FIG. 6, the height of the top 5a gradually decreases as the trough 5b of the V-shaped groove 5 becomes deeper. The relative height of the top 5a and the valley 5b is unchanged, and the cross-sectional area of the V-shaped groove 5 is also substantially constant. However, when the arrangement pitch T of the optical fibers 2 is large and the top part 5a of the V-shaped groove 5 is flat, as shown by the change part 5e of the V-shaped groove 5 shown at the right end of FIG. The flat portion is gradually narrowed.
[0034]
As shown in FIG. 6A, the valley portion 5b of the V-shaped groove 5 is smoothly and gradually deepened, for example, from the position after the longitudinal central portion of the V-shaped groove 5 toward the stepped portion 9 side. It is desirable to go. The positioning of the optical fiber 2 is performed at least in a linear portion where the depth of the valley portion 5b ahead of the center position in the longitudinal direction of the V-shaped groove 5 is not changed.
[0035]
In the linear portion where the opening angle θ does not change, the opening angle of the V-shaped groove 5 is such that the cross-sectional area S1 of the gap 7 and the cross-sectional area S2 of the gap 8 described in FIG. The distance between the substrate 3 and the cover plate 4 is preferably set. When the optical fiber is formed with a high-density array pitch T as shown in FIG. 1C, the opening angle between both side walls of the V-shaped groove 5 in the linear portion exceeds 70 ° and is 100. It is preferable to be less than °.
[0036]
FIG. 6B is a diagram showing a change in the depth of the groove at positions bb, cc, and dd in the longitudinal direction of the V-shaped groove 5 in FIG. 6A. The depth of the valley portion 5b of the V-shaped groove 5 at the bb position is H1 at the bb position, H2 at the cc position, H3 at the dd position, and H1 from the upper surface line of the groove forming portion 3a. <H2 <H3.
[0037]
By forming the V-shaped groove 5 as described above, the gap between the V-shaped groove 5 and the cover plate 4 is formed on the stepped portion 9 side of the groove forming portion 3a as in the example of FIG. Expand gradually. As a result, the cross-sectional area of the resin filling gap on the side of the stepped portion 9 is increased, and the adhesive can easily enter. Therefore, by allowing the adhesive to enter from the stepped portion 9 side toward the tip end side of the substrate by capillary action, the adhesive can be filled smoothly without generating bubbles in the gap. Moreover, since the step part 9 changes gently, the stress concentration with respect to other adhesives (not shown) applied to the rear part can be reduced, and an increase in loss can be prevented.
[0038]
Further, as in the example of FIG. 5, the optical fiber 2 is gradually separated from the contact with the both side walls of the V-shaped groove 5 on the stepped portion 9 side of the groove forming portion 3 a and is in contact with the rear end edge 5 c. Do not float. As a result, the optical fiber 2 is not damaged at the step portion 9 of the groove forming portion 3a, and the occurrence of disconnection can be prevented.
[0039]
The above-described substrate used for the optical fiber array according to the present invention is preferably formed by press molding using upper and lower molds. Since the V-shaped groove is not a straight and uniform shape in the longitudinal direction, machining by grinding is highly controlled and precise, and productivity is not good. However, in the case of press molding, since the mold only needs to be manufactured once, the cost of the mold increases somewhat, but the problem of productivity does not occur. In addition, the V-shaped groove formed by press molding has a uniform and smooth surface roughness compared to the ground one, so that the flow of adhesive into the gap is good and the optical fiber array has high reliability. Substrates and optical fiber arrays can be manufactured.
[0040]
【The invention's effect】
As is clear from the above description, according to the present invention, the gap formed between the optical fiber and the groove of the substrate can be filled with an adhesive without causing bubbles, and the substrate is peeled off. And an increase in loss can be prevented. Moreover, stress concentration and disconnection can be prevented by enlarging the gap on the step side of the groove forming portion.
[Brief description of the drawings]
FIG. 1 is a diagram for explaining the outline of an optical fiber array according to the present invention.
FIG. 2 is a diagram illustrating the flow of the adhesive when the adhesive is applied from the front end side of the substrate.
FIG. 3 is a diagram for explaining a relationship between an opening angle of a V-shaped groove of a substrate and a cross-sectional area of a gap.
FIG. 4 is a view showing another example of the groove shape of the substrate.
5 is a diagram showing the shape of a V-shaped groove of the substrate according to the present invention.
FIG. 6 is a view showing another shape of the V-shaped groove of the substrate according to the present invention .
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 ... Optical fiber array, 2 ... Optical fiber, 2a ... Fiber coating | coated part, 3 ... Board | substrate, 3a ... Groove formation part, 3b ... Flat part, 4 ... Cover plate, 5 ... Groove (V-shaped groove), 5a ... Top part 5b ... trough part, 5c ... rear end edge, 5e ... change part, 6 ... adhesive, 7, 8 ... gap, 9 ... step part.

Claims (5)

溝形成部と平坦部とを段差をつけて形成した基板と蓋板とからなり、前記基板の溝形成部に設けた両側壁が開き角度を持つ複数のV字状溝に、光ファイバを収納配列して前記蓋板で押さえて位置決めし、前記光ファイバと前記基板及び前記蓋板との間に生じる間隙部分に接着剤を充填して接着一体化する光ファイバアレイであって、
前記基板の溝形成部の段差側で、前記V字状溝の開き角度が徐々に広げられ溝頂部の高さが次第に低くされていて、前記光ファイバと前記基板の上面と前記蓋板の下面との間に生じる間隙部分の横断面積をS1とし、前記基板の溝と前記光ファイバとの間に生じる間隙部分の横断面積をS2としたとき、S1>S2であることを特徴とする光ファイバアレイ。
An optical fiber is housed in a plurality of V-shaped grooves, each of which has an opening angle on both side walls provided in the groove forming portion of the substrate, which includes a substrate and a cover plate formed with a step between the groove forming portion and the flat portion. An optical fiber array that is aligned and pressed by the lid plate and is integrated by filling an adhesive into a gap portion formed between the optical fiber and the substrate and the lid plate,
On the step side of the groove forming portion of the substrate, the opening angle of the V-shaped groove is gradually widened and the height of the groove top portion is gradually lowered, and the optical fiber, the upper surface of the substrate, and the lower surface of the lid plate S1> S2, where S1 is the cross-sectional area of the gap formed between the substrate and the optical fiber, and S2 is the cross-sectional area of the gap formed between the groove of the substrate and the optical fiber. array.
溝形成部と平坦部とを段差をつけて形成した基板と蓋板とからなり、前記基板の溝形成部に設けた両側壁が開き角度を持つ複数のV字状溝に、光ファイバを収納配列して前記蓋板で押さえて位置決めし、前記光ファイバと前記基板及び前記蓋板との間に生じる間隙部分に接着剤を充填して接着一体化する光ファイバアレイであって、
前記基板の溝形成部の段差側で、前記V字状溝の深さが徐々に深くされ溝頂部の高さが次第に低くされていて、前記光ファイバと前記基板の上面と前記蓋板の下面との間に生じる間隙部分の横断面積をS1とし、前記基板の溝と前記光ファイバとの間に生じる間隙部分の横断面積をS2としたとき、S1>S2であることを特徴とする光ファイバアレイ。
An optical fiber is housed in a plurality of V-shaped grooves, each of which has an opening angle on both side walls provided in the groove forming portion of the substrate, which includes a substrate and a cover plate formed with a step between the groove forming portion and the flat portion. An optical fiber array that is aligned and pressed by the lid plate and is integrated by filling an adhesive into a gap portion formed between the optical fiber and the substrate and the lid plate,
The depth of the V-shaped groove is gradually increased on the step side of the groove forming portion of the substrate, and the height of the groove top portion is gradually decreased. The optical fiber, the upper surface of the substrate, and the lower surface of the lid plate S1> S2, where S1 is the cross-sectional area of the gap formed between the substrate and the optical fiber, and S2 is the cross-sectional area of the gap formed between the groove of the substrate and the optical fiber. array.
前記光ファイバの外径を125μm、配列ピッチを127μmとし、前記溝の両側壁間の開き角度を70°を超え100°未満としたことを特徴とする請求項1又は2に記載の光ファイバアレイ。  The optical fiber array according to claim 1 or 2, wherein an outer diameter of the optical fiber is 125 µm, an arrangement pitch is 127 µm, and an opening angle between both side walls of the groove is more than 70 ° and less than 100 °. . 請求項1〜3のいずれか1項に記載の光ファイバアレイに用いることを特徴とする光ファイバアレイ基板。  It uses for the optical fiber array of any one of Claims 1-3, The optical fiber array board | substrate characterized by the above-mentioned. プレス成形により形成されていることを特徴とする請求項4に記載の光ファイバアレイ用基板。  The optical fiber array substrate according to claim 4, wherein the optical fiber array substrate is formed by press molding.
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