Liquid Lens Array Bonding With Bessel-Beam Separation
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Solution Overview
Problem
There is a need for fast and efficient methods to manufacture liquid lenses and other workpieces, particularly in a large-scale manner, while ensuring hermetic sealing and mechanical robustness.
Innovation Solution
A laser-based process is used to diffuse absorbing material between substrates, forming bonds and creating fault lines to facilitate the separation of individual liquid lenses from an array, employing an approximated Bessel beam to minimize optical disruption and ensure precise laser energy refocusing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional bonding methods are used to manufacture liquid lenses, then manufacturing speed is slow, but manufacturing precision and hermetic sealing can be maintained
Solution Approach 1:
The patent replaces conventional mechanical bonding methods with a laser-based process. Laser energy is used to diffuse absorbing material between substrates, creating bonds through thermal diffusion rather than mechanical fastening or adhesive application. This substitution enables faster processing speeds while maintaining bond integrity and hermetic sealing.
Solution Approach 2:
The patent changes the physical state and distribution of absorbing material through controlled laser heating. By adjusting laser parameters (energy, duration, focus) and material diffusion parameters (temperature, time), the process achieves rapid bonding. The absorbing material transitions from a discrete strip to a diffused interface layer, creating strong hermetic bonds between substrates.
2Manufacturing precision
If laser energy is used to create fault lines through bonded substrates, then separation precision is improved, but optical disruption increases
Solution Approach 1:
The patent uses an approximated Bessel beam as an intermediary optical structure to deliver laser energy through the bonded substrates. The Bessel beam's unique propagation characteristics allow it to maintain focus over extended distances and refract through the bond interface with minimal disruption. This intermediary beam profile enables precise fault line creation while preserving optical integrity of the final product.
Solution Approach 2:
The patent employs periodic laser pulsing to create fault lines through the bonded substrates. By delivering energy in controlled pulses rather than continuous exposure, the process achieves precise fault line formation while allowing thermal diffusion between pulses. This periodic action minimizes cumulative optical disruption while maintaining separation precision.
3Reliability
If absorption material strip is diffused to create bonds, then hermetic sealing is improved, but manufacturing time increases
Solution Approach 1:
The patent applies absorbing material strips to substrate surfaces before bonding, positioning them in advance where bonds will form. This preliminary placement allows the material to be ready for immediate diffusion when laser energy is applied, eliminating the need for slower alternative bonding methods. The pre-positioned strips enable rapid hermetic seal formation through controlled laser-induced diffusion.
Solution Approach 2:
The absorbing material strip serves multiple functions: it acts as a bonding agent through diffusion, provides hermetic sealing at the substrate interface, and enables laser energy absorption for controlled heating. This multi-functionality consolidates multiple manufacturing steps into a single laser processing operation, reducing overall manufacturing time while ensuring reliable hermetic sealing.
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 method enables rapid and robust manufacturing of liquid lenses with hermetic seals and improved mechanical robustness, allowing for efficient separation and production of individual lenses from an array while maintaining optical integrity.
Implementation Method 1
emitting a first laser energy onto a length and a width of a strip of an absorption material disposed between a first substrate and a second substrate until the strip of the absorption material diffuses into one or more of the first substrate and the second substrate resulting in a bond
Implementation Method 2
the strip of the absorption material diffuses into one or more of the first substrate and the second substrate resulting in a bond
Implementation Method 3
emitting a second laser energy through the workpiece at the bond to create a fault line through the bond, the first substrate, and the second substrate, the second laser energy provided by an approximated Bessel beam, the approximated Bessel beam incident upon the bond having a diameter that is greater than the width of the bond
Data Source
AI summary
A method of forming a bond between substrates and manipulating the bond comprises: emitting a first laser energy onto a strip of an absorption material disposed between a first substrate and a second substrate until the strip diffuses into the first substrate and the second substrate resulting in workpiece with a bond between the first substrate and the second substrate; emitting a second laser energy through the workpiece at the bond to create a fault line through the bond, the first substrate, and the second substrate, the second laser energy provided by an approximated Bessel beam, the approximated Bessel beam incident upon the bond having a diameter that is greater than a width of the bond; and repeating emitting the second laser energy step along a length of the bond to create a series of fault lines through the bond, the series of fault lines forming a contour.