Bendable Substrate Assembly for Precise 3D Optical Path Alignment
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Solution Overview
Problem
Manufacturing complex optics systems with off-axis optical paths is challenging due to high manufacturing complexity, precision requirements, and space constraints, particularly in miniaturized forms, as existing methods require intricate adjustments and large adjusting elements, limiting scalability and cost-effectiveness.
Innovation Solution
A method involving a planar substrate with defined bending edges is used to create a three-dimensional body by bending, allowing for the precise orientation of optical or acoustic devices to form a communications path, including direct or indirect optical paths, within a closed or open structure, facilitating efficient and cost-effective production of complex optics systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complex optics systems with off-axis optical paths are manufactured using existing methods, then the optical path can be adjusted, but the manufacturing complexity and adjustment complexity increase significantly
Solution Approach 1:
The patent applies preliminary action by pre-defining the optical path geometry through the substrate's three-dimensional shape before device assembly. The substrate is manufactured with predetermined bends and folds that automatically establish the correct optical path geometry, eliminating the need for complex post-assembly adjustments of mirrors and optical components.
Solution Approach 2:
The substrate structure serves itself by using its own geometric form to define the optical path. The bends and folds in the substrate automatically position optical components and define light paths without requiring separate adjustment mechanisms, reducing both manufacturing complexity and adjustment requirements.
2Adaptability or versatility
If adjusting elements are added to enable optical path adjustment, then the optical system becomes adaptable, but the space requirements and device size increase
Solution Approach 1:
The patent transitions from two-dimensional planar substrates to three-dimensional folded structures. By bending and folding the substrate in multiple dimensions, the optical path can be configured in complex three-dimensional arrangements while maintaining a compact overall device size, as the optical path length is separated from the device footprint.
Solution Approach 2:
The patent implements nesting by folding the substrate back on itself multiple times, creating a compact nested structure. The optical path winds through the folded substrate layers, allowing long optical paths to be contained within small device volumes, similar to nested dolls where each layer contains the previous one.
3Manufacturing precision
If manual adjustment methods are used for complex optics systems, then the optical path can be configured, but the time consumption and labor requirements increase
Solution Approach 1:
The substrate's three-dimensional geometry is pre-manufactured with the exact optical path configuration required, eliminating the need for time-consuming manual assembly and adjustment of individual optical components. This preliminary structuring enables rapid device assembly and scaling to high-volume production.
Data Source
AI summary
Described are an apparatus and a method for manufacturing a three-dimensional body comprising mutually oriented devices. In accordance with the invention, a substrate having a first and a second substrate region is provided. A first device is provided in the first substrate region. A second device is provided in the first or in the second substrate region. The substrate is bent along at least one bending edge in order to obtain a three-dimensional body. In accordance with the invention, the first device and the second device are oriented to each other by the bending in order to provide a communications path between the same.