Heated Glass Deformation for Shifted Optical Elements
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing optical components with inclined or shifted optical windows are costly and lack flexibility, often requiring high material expenditure and resulting in unsatisfactory surface quality.
Innovation Solution
A method involving a deformation element made of glass or glass-like material, which is deformed to incline and shift optical elements relative to a carrier, using processes like heating and bonding to create optical components with high surface quality and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional embossing and etching processes are used to create recesses in the lid, then the optical windows can be formed, but the surface quality becomes unsatisfactory and material expenditure increases
Solution Approach 1:
The patent changes the physical state of the glass material from solid to viscous by heating it to above its softening point, enabling deformation processing that achieves high surface quality while reducing material waste compared to conventional embossing and etching methods
Solution Approach 2:
The patent utilizes the phase transition of glass from solid to viscous state through heating above the softening point, allowing the glass to be deformed into the required optical window shapes without the material waste associated with conventional removal-based methods
2Manufacturing precision
If glass deep drawing or glass molding is used to manufacture optical components, then the optical windows can be formed, but the surface quality is unsatisfactory
Solution Approach 1:
The patent changes the temperature parameter to above the glass softening point, enabling the glass to flow and conform to the mold surface, which produces high surface quality optical windows while maintaining wafer-level processing efficiency
3Volume of moving object
If wet-chemical etching is used to create recesses in the silicon cover wafer, then the required depth can be achieved, but the surface quality and material utilization deteriorate
Solution Approach 1:
The patent replaces the chemical etching process with a thermal-deformation process, where heating the glass above its softening point allows mechanical deformation to create the required recesses, achieving both the necessary depth and high surface quality
4Ease of operation
If the carrier wafer is separated before encapsulation, then the microsystems can be mounted, but the production process becomes more complex and time-consuming
Solution Approach 1:
The patent performs the encapsulation process before carrier wafer separation, creating a wafer-level packaging process where the lids are formed and bonded to the carrier wafer containing multiple microsystems, enabling parallel processing and reducing overall process complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables cost-effective production of optical components with inclined or shifted optical windows, maintaining high surface quality and allowing for parallel production of multiple components, reducing material waste and manufacturing costs.
Implementation Method 1
heating and deforming at least a part of the deformation region such that the functional element shifts and/or inclines at least partially in relation to the carrier
Implementation Method 2
The deformation element contains glass and/or a glass-like material... bringing the deformation element into contact with the carrier... heating and deforming at least a part of the deformation region
Implementation Method 3
deforming at least a part of the deformation region such that the functional element shifts and/or inclines at least partially in relation to the carrier
Implementation Method 4
Connecting the functional element to the deformation element during the method step of applying the functional element to the deformation element and/or during the method step of heating and deforming the deformation region
Data Source
Figure 1a~1b
Figure 2a~2d
Figure 3a~3h
AI summary
The invention relates to a method for producing optical components, a first contact surface being formed by bringing a deformation element into contact with a substrate and a second contact surface being formed by applying a functional element to the deformation element, the second contact surface at least partially overlapping the first contact surface such that a deformation region is formed by the region of the deformation element lying between the overlapping regions of the two contact surfaces. At least part of the deformation region is heated and deformed in such a way that the functional element is displaced, in particular shifted and/or inclined and the functional element is connected to the deformation element during the method step of applying the functional element to the deformation element and/or during the method step of heating and deforming the deformation region.