Unitary Lens Array With Absorbent Trenches
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The assembly of lens arrays is time-consuming and prone to misalignment errors due to the conventional method of using a lens alignment frame, which can lead to errors in image capture and processing, especially when producing three-dimensional images.
Innovation Solution
A method of forming a crosstalk-suppressed lens array by creating trenches in a unitary lens preform and filling them with a light absorbent material to ensure accurate alignment and positioning of individual lenses, while preventing optical crosstalk, using techniques like milling, laser ablation, or etching to form laterally offset and vertically overlapping trenches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a lens alignment frame is used to assemble individual lenses, then the relative positioning of lenses can be achieved, but the assembly process becomes time-consuming and prone to misalignment errors
Solution Approach 1:
The patent merges the alignment frame and individual lenses into a single unitary lens array preform. The preform is formed as one integrated piece containing multiple lens elements with predetermined relative positions, eliminating the need for separate assembly operations and alignment frames. This combining approach resolves the contradiction by achieving both high positioning accuracy (through precise preform fabrication) and high productivity (through direct use of the preform without assembly).
Solution Approach 2:
The patent performs the alignment and positioning action in advance during the preform fabrication process. The relative positions of lens elements are predetermined and fixed in the unitary preform before the lens array is finalized. This preliminary establishment of precise positioning eliminates the need for time-consuming assembly operations later, resolving the contradiction between positioning accuracy and assembly time.
2Reliability
If individual lenses are assembled in a frame, then the array can be constructed, but misalignment errors occur that cause errors in image capture and processing
Solution Approach 1:
By merging all lens elements into a single unitary preform, the patent eliminates the interfaces and alignment operations between separate components. The predetermined relative positions within the preform ensure consistent and accurate positioning, directly improving image capture reliability by eliminating misalignment errors that would otherwise occur during assembly.
3Object-affected harmful factors
If trenches are formed in the unitary lens preform and filled with light absorbent material, then optical crosstalk between individual lenses is prevented, but the process requires additional manufacturing steps
Solution Approach 1:
The patent extracts or removes material from the unitary preform to create trenches between adjacent lens elements. These trenches are then filled with light absorbent material to block optical crosstalk. By taking out material to create isolation barriers, the patent effectively prevents harmful optical interference between lenses while maintaining the overall unitary structure.
4Manufacturing precision
If trenches are formed using milling, laser ablation, or etching, then accurate lens positioning is maintained, but the manufacturing process becomes more complex
Solution Approach 1:
The patent replaces traditional mechanical assembly methods with laser ablation or etching processes to form trenches in the preform. These non-mechanical or minimally mechanical processes maintain the precision of lens positioning by working directly on the preform without requiring physical handling or alignment operations. The substitution of mechanical assembly with controlled material removal and deposition simplifies the overall manufacturing flow while maintaining high precision.
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
This approach ensures accurate relative alignment and positioning of lenses, minimizing crosstalk and maintaining the unitary structure of the lens array, thereby improving the reliability of image capture and processing while reducing assembly time and errors.
Implementation Method 1
filling them with a light absorbent material to ensure accurate alignment and positioning of individual lenses, while preventing optical crosstalk
Implementation Method 2
using techniques like milling, laser ablation, or etching to form laterally offset and vertically overlapping trenches
Data Source
Figure 1~2
Figure 3~4C
Figure 4D~5
AI summary
The invention provides a method of forming a crosstalk-supressed lens array, the method comprising: providing a unitary lens array preform having plural individual lenses; forming a trench between the individual lenses; providing in the trench a light absorbent material for absorbing optical crosstalk between the individual lenses. The invention also provides a lens array formed using this method.