Wafer-Level Lens Assembly with Spacer Structure
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Solution Overview
Problem
Electronic imaging devices face image quality degradation due to imprecise focusing of optical lens assemblies, leading to 'out-of-focus' issues, which are not adequately addressed by existing technologies.
Innovation Solution
A method involving a lens assembly with a spacer structure between two lens layers on transparent substrates, where the spacer layers directly contact the substrates, allowing precise control of the distance between lenses without adhesives, and the substrates can be thinned to adjust the focal length, enabling accurate and precise image projection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If adhesive is used to bond lens layers, then lens layers can be joined, but precise distance control and alignment are degraded
Solution Approach 1:
The patent removes the adhesive layer from the bonding process entirely. Instead of using adhesive to bond lens layers, the invention uses a spacer structure with protrusions that directly contact and position lens substrates, eliminating the adhesive intermediary and enabling precise alignment through mechanical contact alone.
Solution Approach 2:
The patent introduces a spacer structure with protrusions as a mechanical intermediary between lens layers. These protrusions directly contact the lens substrates to establish precise spacing and alignment, replacing the adhesive intermediary and providing controllable, precise distance maintenance without the alignment degradation caused by adhesive application.
2Manufacturing precision
If focal length is adjusted after assembly, then image quality can be optimized, but manufacturing time and complexity increase
Solution Approach 1:
The patent performs preliminary action by pre-calculating and pre-setting the required substrate thickness during the lens design and manufacturing phase. The substrate is thinned to a specific thickness that corresponds to the desired focal length, allowing the focal length to be accurately determined before assembly without requiring post-assembly adjustment.
Solution Approach 2:
The patent changes the physical parameter of substrate thickness to control focal length. By thinning the lens substrate to a predetermined thickness during manufacturing, the focal length is directly controlled through this parameter change, eliminating the need for time-consuming post-assembly adjustments while maintaining high precision.
3Manufacturing precision
If substrate is thinned to adjust focal length, then focal precision is improved, but substrate strength decreases
Solution Approach 1:
The patent uses the spacer structure with protrusions to counterbalance the structural weakness caused by substrate thinning. The spacer protrusions provide mechanical support and reinforcement to the thinned substrate, compensating for the loss of strength while maintaining the reduced thickness required for precise focal length control.
Solution Approach 2:
The patent creates a composite structure by combining the thinned lens substrate with the spacer structure. This composite construction allows the substrate to be thinned for optical precision while the spacer material provides the necessary mechanical strength and support, achieving both precision and durability simultaneously.
Data Source
AI summary
According to embodiments of the invention, a lens assembly and method for forming the same is provided. The method includes providing a first lens layer having a first transparent substrate and a first lens on the first transparent substrate, providing a second lens layer having a second transparent substrate and a second lens on the second transparent substrate, forming a spacer structure between the first lens layer and the second lens layer, and thinning the first transparent substrate to a first thickness after the spacer is formed.