Metallized Camera Window Batch Coating and Hermetic Sealing
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Solution Overview
Problem
Conventional metallized camera windows require a tedious manual alignment process for anti-reflective coating (ARC) and metal layer deposition, limiting handling time and yield due to the need for non-overlapping layers and multiple masking steps.
Innovation Solution
A method where the anti-reflective coating covers the entire interior and exterior surfaces of the window, with a metal layer extending onto the periphery, allowing for batch deposition and alignment without masking, and a solder joint is formed between the metal layer and a metallic lid for hermetic sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual alignment process is used for ARC and metal layer deposition, then layer alignment precision is improved, but productivity deteriorates
Solution Approach 1:
The patent applies preliminary action by pre-forming the metal layer on the window perimeter before ARC deposition, and pre-aligning multiple windows on the substrate. This eliminates the need for manual alignment during the deposition process, as the layers are already positioned correctly before the deposition begins, thus improving productivity while maintaining precision.
Solution Approach 2:
The patent merges multiple windows onto a single substrate, allowing batch processing of ARC and metal layer deposition. By combining multiple windows into one assembly, the deposition process can be performed simultaneously on all windows without individual manual alignment, significantly improving productivity while maintaining consistent layer alignment across all windows.
2Manufacturing precision
If two masking steps are used for non-overlapping layers, then manufacturing precision is improved, but device complexity deteriorates
Solution Approach 1:
The patent extracts and eliminates the masking steps from the deposition process. By pre-forming the metal layer on the window perimeter and pre-aligning windows on the substrate, the need for masking during deposition is completely removed. This simplifies the device complexity while maintaining layer alignment precision through the pre-established geometric relationships.
3Manufacturing precision
If manual alignment process is used, then layer alignment precision is improved, but quantity of substance deteriorates
Solution Approach 1:
The patent merges multiple windows into a single batch processing unit on a common substrate. This allows simultaneous deposition of ARC and metal layers on all windows in the batch, improving yield by processing multiple units at once. The pre-alignment and pre-formed metal layers ensure consistent precision across all windows without requiring individual manual handling, thus improving overall productivity and yield.
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 approach simplifies the alignment process, enhances yield, and facilitates the hermetic sealing of focal plane arrays by enabling simultaneous coating and metal deposition on multiple windows, improving the efficiency and reliability of the metallized camera window assembly.
Implementation Method 1
A metal layer is bonded to the perimeter surface of the window
Implementation Method 2
An anti-reflective coating (ARC) is bonded to the interior surface of the window
Implementation Method 3
The method includes joining the window to a lid by forming a solder joint between a metallic portion of the lid and the metal on the perimeter of surface of the window
Data Source
Figure 1
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AI summary
An optical assembly includes a window having an interior surface and an opposed exterior surface. A perimeter surface connects between the interior surface and the exterior surface. A metal layer is bonded to the perimeter surface of the window. An anti-reflective coating (ARC) is bonded to the interior surface of the window. A metallic lid is joined to the metal layer for enclosing a focal plane array (FPA) aligned with the window.