Multistage Light Diffraction Alignment With 3D Spacer Marks
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Solution Overview
Problem
Existing multistage light diffraction devices face challenges in accurately adjusting the positions and orientations of light diffraction element units relative to input light, as well as defining the correct intervals between these units, which affects their ability to exert a desired action on the light.
Innovation Solution
The introduction of a three-dimensional alignment mark on the light diffraction element units, which allows for both in-plane adjustment and precise interval definition between adjacent units, achieved through a manufacturing method that includes forming, layering, adjusting, and fixing these units using stereolithography and ultraviolet curable resin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a two-dimensional alignment mark is used, then the alignment mark can be obtained by patterning a thin film material by photolithography, but it cannot define the intervals between adjacent light diffraction element units in the layering direction
Solution Approach 1:
The patent transforms the alignment mark from a two-dimensional planar structure to a three-dimensional structure with significant thickness (several μm). This dimensional change enables the alignment mark to serve dual functions: maintaining ease of manufacture through photolithography patterning while simultaneously defining the vertical intervals between adjacent light diffraction element units in the layering direction, thereby resolving the contradiction between manufacturing ease and interval definition precision
2Adaptability or versatility
If light diffraction element units are layered to form a multistage device, then the device can perform complex optical operations, but it becomes difficult to accurately adjust positions and orientations of each unit
Solution Approach 1:
The patent introduces a three-dimensional alignment mark as an intermediary reference structure between adjacent light diffraction element units. This alignment mark serves as a mediator that enables accurate positioning and orientation adjustment of each unit relative to others in the layered stack, thereby facilitating precise assembly of the multistage device while maintaining its optical versatility
3Manufacturing precision
If the thickness of the alignment mark is increased to define intervals, then the interval definition becomes possible, but the alignment mark structure becomes more complex
Solution Approach 1:
The patent designs the three-dimensional alignment mark to perform multiple functions simultaneously: it serves as an in-plane alignment reference for position and orientation adjustment, and as a vertical spacer to define intervals between adjacent light diffraction element units. This multi-functionality reduces the need for separate structural elements, thereby managing device complexity while achieving precise interval definition
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 solution enables accurate alignment and interval control, ensuring that the light diffraction elements function optimally by maintaining the desired positional and orientational relationships, thereby enhancing the performance of the multistage light diffraction device.
Implementation Method 1
a step of curing the ultraviolet curable resin by ultraviolet irradiation
Data Source
AI summary
A light diffraction element unit includes an optically-transparent substrate; a light diffraction element disposed on a main surface of the optically-transparent substrate; and a three-dimensional alignment mark disposed on the main surface in a vicinity of the light diffraction element and having a thickness greater than a thickness of the light diffraction element.