JP2015045875A - 溶接接合方法及び溶接接合されたコンポーネントを有するデバイス - Google Patents
溶接接合方法及び溶接接合されたコンポーネントを有するデバイス Download PDFInfo
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- JP2015045875A JP2015045875A JP2014212393A JP2014212393A JP2015045875A JP 2015045875 A JP2015045875 A JP 2015045875A JP 2014212393 A JP2014212393 A JP 2014212393A JP 2014212393 A JP2014212393 A JP 2014212393A JP 2015045875 A JP2015045875 A JP 2015045875A
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- Physics & Mathematics (AREA)
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- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Optical Couplings Of Light Guides (AREA)
- Mounting And Adjusting Of Optical Elements (AREA)
- Mechanical Coupling Of Light Guides (AREA)
- Adhesives Or Adhesive Processes (AREA)
Abstract
Description
一実施形態例にしたがえば、2つのフォトニックコンポーネント20を、間に永久接合を形成して集成した(図1A,1B,2A及び2Bを見よ)。さらに詳しくは、光素子21A(本例では光ファイバ)を金属基板22A(本例では304ステンレス鋼版基板)に載せて基板に貼り付け、第1のフォトニックコンポーネント20を形成した。別の基板22B上に光ファイバ21Bを載せて、別のフォトニックコンポーネント20を作製した。第1のコンポーネント20の合わせ面20Aの1つにテーパ面Wがあることに注意されたい。光ファイバ導波路21Aの入力端Aに光が与えられたときに光ファイバ導波路21Bの出力端Bから光が出てくるように、2つのフォトニック素子20を相互に密接させて配置した。2つのフォトニックコンポーネント20をピーク結合(光ファイバ導波路21Bの出力端Bで測定した出力パワーが最大になる結合)帯に位置合わせし、次いでUV硬化性接着剤(例えば、米国コロラド州ブレックンリッジのElectronic Materials社から入手できる、OPTOCAST(商標)3415)を用いて所定の位置に貼り付けて、‘T’接合を形成した。続いて貼付けアセンブリにレーザ溶接を施した。本実施形態例において、発明者等は3ミリ秒のパルス幅で動作させたパルスNd:YAGレーザを用い、溶接スポット毎にほぼ0.9Jのエネルギーを印加した。本実施形態例において、溶接スポット径dはほぼ450μmであった(溶接スポット位置については図1及び2A、2Bを見よ)。
コンポーネントを位置合わせし、それぞれを所定の位置に貼り付け、レーザ溶接を実施する方法は、様々な合わせ面形状に拡張することができる。上の実施例1では、合わせ面の一方の面がテーパ面である。本実施例ではテーパ面がなく、アセンブリ全体が‘T’接合のように見えるように表面が変えられる(作製したデバイス10の、略図については図3を、図については図4A及び4Bを見よ)。さらに詳しくは、図4Aはデバイス10の上面図を示し、図4Bは図4Aの作製されたデバイス10の側面図の一部を示す。溶接後シフト誘起スループットパワー変動の平均は、光源変動を含めて、約1.8%(すなわち、P2>0.982P1)であった。本実施形態例において、作製したデバイス10の熱サイクリングの結果の変動は2%未満(すなわちP2の変化が2%未満)であった。このタイプの‘T’接合形状は、それぞれのコンポーネント20を単純な直方体ブロックとすることができるから、好ましい。そのような‘T’接合コンポーネントアセンブリの別の利点は、作製において寸法及び許容値が変わったとしても、溶接接合は対称的であり、したがって対向する横方向溶接力を印加するであろうということである。すなわち、釣り合いのとれたレーザビームパワー及び布置により、得られる対称的な溶接位置(溶接スポット位置)は等しい、対向する力を加え、大部分は相互に打ち消しあって、硬化エポキシ樹脂接合により補償される必要がある残留応力が低減される。
本発明のデバイスアセンブリ方法は軸対称デバイスにも適用することができる。本実施形態において、304ステンレス鋼代用デバイス(すなわち、光素子を有していないコンポーネント)を、接着剤を用いて集成した。いくつかの代用デバイスは(米国カリフォルニア州ランチョキューカモンガ(Rancho Cucamonga)のThe Original Super Glue Corporation社の、Super Glue Gel(登録商標)のような)シアノアクリレートゲルの小ビードを3個用いて接合し、他の代用デバイスは(米国テキサス州サルファスプリングス(Sulphur Springs)のJ-B Weld CompanyのJ-B Kwik(登録商標)のような)充填2成分エポキシ樹脂を用いて接合した。本実施例に用いた円筒形金属基板22A(代用コンポーネント20)に、45°のテーパ角でフランジを付け、ベース代用コンポーネント20’(金属基板22A)に取り付けた(図7を見よ)。接合した代用デバイスを発明者等の試験設備にクランプで固定し、それぞれの代用デバイスのコンポーネントの変位を(米国メリーランド州アナポリス(Anaplis)のPhiltec社)のPhiltec RC20光ファイバセンサ変位プローブを3本用いてモニタした。他のプローブも用いた。接合した代用デバイスは、120°ずつ離し、フェルール中心線から25°傾けた3本のビームで溶接した。この試験構成が図7に簡略に示される。パワーが比較的低いレーザビーム(本実施例におけるレーザ条件は、溶接スポットあたり0.9J,3ミリ秒パルス幅及びほぼ450μmの溶接スポット径とした)を2つの金属コンポーネントの間の界面に向けた。コンポーネントを溶接し合わせた後、横方向溶接後シフトを測定した。シアノアクリレートゲルを用いて接着した3つの代用デバイスの1つからの代表的な試験結果を図8に示す。図8は図7に示した軸対称代用試験デバイスの機械的変位の測定値を示す。図8の3本のトレースは3本の変位センサの出力を表す。図8において、y軸はμm単位であり、x軸は、秒単位で測定した、時間を表す。
20 コンポーネント
21A,21B 光素子
22A,22B 基板
23 接着剤
25 境界
28 溶接スポット
Claims (15)
- 光素子を有する光エレクトロニクスコンポーネント及び/またはフォトニックコンポーネントを集成する方法において、前記方法が、
(i) 少なくとも2つの光エレクトロニクスコンポーネント及び/またはフォトニックコンポーネントを提供する工程、
(ii) 前記光エレクトロニクスコンポーネント及び/または前記フォトニックコンポーネントを、
(a) 隣接する前記コンポーネントの間における光路により有効となる、前記コンポーネントの間の光結合を与え、
(b) 前記コンポーネントの隣接部分の間隔dを、0μm≦d≦100μmに、維持する、
ために、互いに対して位置合わせし、相互に密接させて配置する工程、
(iii) 前記コンポーネントを、
(a) 前記少なくとも2つのコンポーネントが複数の接着剤スポットによって相互に連結され、前記接着剤スポットが互いに対して対称に配置されるように、前記コンポーネントの間における前記光路ではない、前記コンポーネントの間の境界の外周縁に沿って接着剤を塗布し、
(b) 前記コンポーネントの間の光結合を維持しながら前記接着剤を硬化または固化させる、
ことによって、相互に接着させる工程、及び
(iv) 前記コンポーネントの間の光結合を維持しながら前記コンポーネントをレーザ溶接し合わせる工程であって、前記レーザ溶接が、前記コンポーネントの間の光結合面から1mm以内の溶接面において行われる工程、
を含むことを特徴とする方法。 - 前記溶接面は、前記光結合面と一致することを特徴とする請求項1に記載の方法。
- 前記レーザ溶接工程が生じさせる隣接するコンポーネントのいずれの1つの位置のシフトも1μmより小さく、レーザ溶接中に前記光結合が、少なくともある程度は、前記硬化または固化した接着剤の構造剛性によって維持されることを特徴とする請求項1に記載の方法。
- 前記接着剤の特徴が、5GPa〜100GPaの剛性率、1秒〜90秒の硬化時間及び硬化中の1μm未満の収縮Cであることを特徴とする請求項1に記載の方法。
- 前記接着剤が、UV硬化性エポキシ樹脂、熱硬化性エポキシ樹脂、熱可塑性接着剤、熱硬化性接着剤、シアノアクリレート、ポリウレタン、シリコーンまたはポリイミドからなる群から選ばれることを特徴とする請求項1に記載の方法。
- 前記レーザ溶接工程が、直径が50μm〜1mmの溶接スポットを少なくとも1つ形成することを特徴とする請求項1に記載の方法。
- (i) 前記コンポーネントを前記接着剤を用いて相互に接合させる前に、前記コンポーネント間の光出力パワーまたは光結合効率を測定する工程、及び
(ii) 前記コンポーネントを前記接着剤を用いて相互に接着させながら、前記コンポーネント間の光出力パワーまたは光結合効率を測定する工程、
をさらに含むことを特徴とする請求項1に記載の方法。 - (i) 前記コンポーネントを前記接着剤を用いて相互に接合させる前に、前記コンポーネント間の光出力パワーP1または光結合効率E1を測定する工程、及び
(ii) 前記コンポーネントを相互にレーザ溶接している間、
(a) 溶接後の光出力パワーP2がP2≧0.9P1であるように、前記光出力パワーを、または
(b) 溶接後の前記コンポーネント間の光結合効率E2がE2≧0.9E1であるように、前記光結合効率を、
維持する工程、
をさらに含むことを特徴とする請求項1に記載の方法。 - (i) 前記コンポーネントを前記接着剤を用いて相互に接合させる前に、前記コンポーネント間の光出力パワーP1または光結合効率E1を測定する工程、
(ii) 前記コンポーネントを前記接着剤を用いて相互に接合させながら、前記コンポーネント間の光出力パワーPaまたは光結合効率Eaを測定する工程、
(iii)前記接着剤を硬化または固化させながら、前記コンポーネント間の光出力パワーPCまたは光結合効率ECを測定する工程、及び
(iv) 前記コンポーネントを相互にレーザ溶接しながら、前記コンポーネント間の光出力パワーPwまたは光結合効率Ewを測定する工程、
をさらに含むことを特徴とする請求項1に記載の方法。 - 前記溶接がパルスNd:YAGレーザを用いて実施されることを特徴とする請求項9に記載の方法。
- 前記溶接が、溶接スポットあたり0.5J〜2.5JでNd:YAGレーザを動作させ、1〜5ミリ秒のレーザパルス幅を用いて溶接することによって実施され、レーザスポットの直径が250μm〜1mmであることを特徴とする請求項10に記載の方法。
- デバイスにおいて、
(i) 互いに近接して配置された、それぞれが少なくとも1つの光素子を有する、少なくとも2つのコンポーネントを有し、
(ii) 前記少なくとも2つのコンポーネントの内の少なくとも1つのコンポーネントの前記少なくとも1つの光素子が前記少なくとも2つのコンポーネントの内の別の1つのコンポーネントの前記少なくとも1つの光素子に光結合されており、
(iii) 前記2つのコンポーネントの間に形成された境界の周縁に配置されている、少なくとも1つの溶接スポット及び複数の接着剤スポットを有し、前記少なくとも1つの溶接スポットが、前記コンポーネント間の光結合面から1mm以内の溶接面に位置する、
ことを特徴とするデバイス。 - 前記溶接面は、前記光結合面と一致することを特徴とする請求項12に記載のデバイス。
- 前記接着剤が、UV硬化性または熱硬化性の接着剤、熱可塑性接着剤、シアノアクリレート、ポリウレタン、シリコーンまたはポリイミドであることを特徴とする請求項12に記載のデバイス。
- 前記少なくとも1つの溶接スポットが250μm〜1mmの断面を有し、前記少なくとも2つのコンポーネントが前記複数の接着剤スポットによって相互に連結され、前記接着剤スポットが互いに対して対称に配置されることを特徴とする請求項12に記載のデバイス。
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JP2000162467A (ja) * | 1998-11-25 | 2000-06-16 | Kyocera Corp | 光導波路と光ファイバとの接続構造 |
JP2005341522A (ja) * | 2004-04-27 | 2005-12-08 | Kyocera Corp | カメラモジュール及びそれを用いた車載用カメラ装置並びにそれらの製造方法 |
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WO2010059898A3 (en) | 2010-08-26 |
US8790483B2 (en) | 2014-07-29 |
CN102264503B (zh) | 2014-03-12 |
TW201029787A (en) | 2010-08-16 |
JP2012510079A (ja) | 2012-04-26 |
WO2010059898A2 (en) | 2010-05-27 |
US20150131949A1 (en) | 2015-05-14 |
US20100129647A1 (en) | 2010-05-27 |
CN102264503A (zh) | 2011-11-30 |
TWI386268B (zh) | 2013-02-21 |
KR20110095910A (ko) | 2011-08-25 |
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