Dam Structure Groove Alignment Device for Lens Warpage
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Solution Overview
Problem
The warpage of lens substrates during the replication or bonding process leads to alignment errors between lenses and spacers in light sensing devices, affecting the optical performance of the final device.
Innovation Solution
An alignment device comprising a dam structure with a groove on one substrate and a post on the corresponding substrate, which guides the post into the groove during bonding, ensuring accurate alignment despite substrate warpage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If alignment marks are used for substrate alignment, then alignment process is simplified, but substrate warpage causes alignment errors between lenses and spacers
Solution Approach 1:
The patent applies preliminary action by forming the dam structure with groove and post alignment features on the substrates before the bonding process. These alignment features are pre-positioned to compensate for expected warpage, ensuring that when substrates are bonded, the lenses and spacers align accurately despite substrate deformation during processing
Solution Approach 2:
The patent introduces dam structures with grooves and posts as intermediary alignment elements between the alignment marks and the actual lens-spacer alignment. These intermediary features provide a mechanical reference that maintains alignment accuracy even when the substrates warp during bonding, acting as a mediator that decouples the alignment reference from the deforming substrate surface
2Productivity
If substrates are bonded after alignment mark alignment, then bonding process is efficient, but warpage causes misalignment between corresponding lenses and spacers
Solution Approach 1:
The alignment features (dam structure with groove and post) are formed on the substrates in advance before bonding. This preliminary structuring ensures that when efficient bonding is performed, the pre-positioned alignment features maintain the correct relative positioning of lenses and spacers throughout the bonding process, preventing warpage-induced misalignment
Solution Approach 2:
The patent segments the alignment function into distinct structural elements: the dam structure, the groove, and the post. This segmentation allows each element to perform a specific alignment function independently, enabling efficient bonding while maintaining precision through the distributed alignment features rather than relying on a single alignment mark system
Data Source
AI summary
An alignment device and applications thereof are disclosed. The device comprises a dam structure disposed on a first substrate, and a post disposed on a second substrate at a position corresponding to the dam structure. The dam structure comprises a groove. The post is disposed in the groove of the dam structure when bonding the first and second substrates.