Lens Master Devices for High-Precision Imaging Profiles

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Solution Overview

Problem

Existing lens fabrication techniques, such as lithography and reactive ion etching, are limited in creating desired shapes and sizes for lens structures, leading to inaccurate profiles in imaging devices.

Innovation Solution

A method involving high-precision shaping processes like injection molding and diamond turning to form lens masters with specific dimensions and materials, which are then used to create lens templates and structures with enhanced accuracy and precision.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If lithography and reactive ion etching techniques are used to form lens structures, then the fabrication process can be performed, but the ability to create desired shapes and sizes and achieve accurate profiles is limited

Engineering Contradiction:

Improvelens structure profile accuracyVSAvoidfabrication process complexity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent introduces a mold as an intermediary tool that contains the desired lens shape and size. The mold is formed using high-precision techniques, and lens structures are created by injecting material into the mold or using the mold to define the final shape. This intermediary approach allows complex lens geometries to be achieved with high accuracy while simplifying the overall fabrication process.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces traditional lithography and reactive ion etching processes with injection molding techniques. Instead of using photolithography to pattern lenses, the invention uses mechanical injection of material into a pre-formed mold, which provides superior control over lens shape, size, and profile accuracy.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Shape

If traditional lithography and etching are used for lens fabrication, then the process can be completed, but the lens structures fail to achieve the desired shapes and sizes

Engineering Contradiction:

Improvelens shape accuracyVSAvoidlens dimension precision

Core Design Contradiction:

ShapeVSManufacturing precision

Solution Approach 1:

The patent creates the mold first with the precise desired shape and size before fabricating the lens structures. The mold is prepared using high-precision techniques, and then lens material is injected into the mold to replicate the exact geometry. This preliminary action ensures that the final lens structures achieve the desired shapes and dimensions with high accuracy.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent changes the fabrication approach from top-down lithography to bottom-up injection molding. This parameter change in the manufacturing method enables superior control over lens geometry, allowing achievement of complex shapes and precise dimensions that were not possible with traditional lithography and etching.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS8982469B2Lens master devices, lens structures, imaging devices, and methods and apparatuses of making the same

Publication Date: 2015.03.17 MICRON TECHNOLOGY INC

AI summary

A method and apparatus providing a lens master device and use of the same to form a lens template and/or a lens structure. The method includes obtaining a plurality of individual lens masters, each of which has a shaped portion defining at least a portion of a lens structure to be formed. The lens masters are affixed onto a supporting structure to form a lens master device.