Lens Assembly Thermal Stability via Glue Buffer Removal
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Solution Overview
Problem
Existing lens assemblies face challenges with thermal stability, reliability, and strength due to the presence of glue buffer areas which cause resistance issues during thermal cycling and can lead to the entire film peeling off, while also limiting the reduction of pitches between adjacent lenses, thereby affecting manufacturing efficiency and cost.
Innovation Solution
A method for forming a lens assembly involves using a mold substrate with recesses to fill lens precursor material, irradiating light to transform the material into lenses without forming a hardened glue buffer area, and removing excess material to enhance thermal stability and reduce lens spacing, allowing for higher density and improved processing throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a glue buffer area is used to fill the space between lenses, then the lenses are held in place, but thermal stability deteriorates and film peeling occurs during thermal cycling
Solution Approach 1:
The patent removes the glue buffer area entirely from the lens assembly structure. By eliminating this problematic component, the invention avoids the thermal cycling issues and film peeling that occur with traditional glue-based holding methods, while still maintaining lens positioning through alternative means.
Solution Approach 2:
The patent divides the substrate surface into distinct lens regions separated by scribe lines, rather than using a continuous glue buffer area. This segmentation allows each lens to be independently positioned and held without the thermal instability problems associated with continuous adhesive layers.
2Strength
If a glue buffer area is present between lenses, then lenses are secured, but the pitch between adjacent lenses cannot be reduced
Solution Approach 1:
By removing the glue buffer area, the invention eliminates the minimum spacing requirement that previously existed between lenses. This allows the pitch between adjacent lenses to be reduced to less than 900 μm, enabling higher lens density on the substrate.
Solution Approach 2:
The use of scribe lines to define lens regions replaces the need for glue buffer areas, allowing lenses to be positioned closer together while maintaining secure attachment through the substrate structure itself rather than through adhesive layers.
3Reliability
If traditional lens assembly methods are used, then lenses can be formed, but fabrication time and cost increase
Solution Approach 1:
The patent combines multiple lens formation operations into a single substrate processing step. By forming multiple lenses on one substrate simultaneously and using a unified holding structure without glue buffer areas, the invention reduces the number of fabrication steps, decreases manufacturing time, and lowers costs while maintaining high lens assembly quality.
Solution Approach 2:
The invention processes multiple lenses in parallel on a single substrate with standardized scribe line definitions, enabling efficient batch production. This segmented approach to lens formation and holding allows for scalable manufacturing without the time-consuming individual assembly steps required by traditional glue-based methods.
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
The solution improves thermal stability, reliability, and strength of the lens assembly by eliminating the glue buffer area, preventing film peeling, and reducing the distance between lenses, thereby enhancing manufacturing efficiency and reducing fabrication time and cost.
Implementation Method 1
irradiating a light on the second surface of the transparent substrate to transform at least a portion of the lens precursor material on the first surface of the transparent substrate into a lens
Data Source
AI summary
A method for forming a lens assembly is provided, including: providing a mold substrate, wherein at least a recess is formed from a surface of the mold substrate; providing a transparent substrate; disposing a lens precursor material on the surface of the mold substrate or on a first surface of the transparent substrate; disposing the mold substrate on the transparent substrate such that at least a portion of the lens precursor material is filled in the recess; disposing a mask on a second surface of the transparent substrate to partially cover the transparent substrate; after the mask is disposed, irradiating a light on the second surface of the transparent substrate to transform at least a portion of the lens precursor material on the first surface of the transparent substrate into a lens; and removing the mask and the mold substrate from the transparent substrate and the lens.