Micro-Spacer Optical Assemblies for Compact Air Gaps
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Solution Overview
Problem
Manufacturing optical and optoelectronic assemblies with air or vacuum gaps between optical elements is challenging due to increased overall height, which is undesirable in space-constrained applications, and chemical interactions between optical elements can impact their performance.
Innovation Solution
The use of micro-spacers, composed of adhesive materials, is introduced to create thin air or vacuum gaps between optical elements, allowing for the separation of these elements while maintaining a compact module height, utilizing techniques like screen-printing, auger valve dispensing, or jetting to form and place the spacers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If air or vacuum gaps are introduced between optical elements, then chemical interactions between optical elements are prevented, but the overall height of the assembly increases
Solution Approach 1:
The patent introduces micro-spacers as intermediary elements between optical components. These spacers are formed from curable material deposited in annular patterns on optical elements. The micro-spacers create thin air or vacuum gaps that prevent chemical interactions while maintaining compact overall height through precise control of spacer thickness and positioning.
Solution Approach 2:
The patent employs parameter changes by controlling the thickness of micro-spacers to be in the range of 20-50 microns, and by adjusting the curing process of the spacer material. This allows optimization of the gap thickness to prevent chemical interactions while minimizing the increase in overall assembly height.
2Reliability
If micro-spacers are used to create gaps between optical elements, then chemical interactions are prevented and optical performance is maintained, but manufacturing complexity increases
Solution Approach 1:
The patent merges multiple functions into the micro-spacer structure. The same curable material deposition process that forms the spacers also creates alignment features and defines gap dimensions. The annular pattern of spacers simultaneously provides mechanical support, chemical isolation, and optical alignment, reducing the need for separate components.
Solution Approach 2:
The patent applies preliminary action by depositing and partially curing the micro-spacer material before final assembly. This preliminary positioning and partial curing allows for precise gap formation and alignment to be established early in the manufacturing process, simplifying subsequent assembly steps.
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 enables the creation of optical and optoelectronic assemblies with thin air or vacuum gaps without significantly increasing the overall height, preventing chemical interactions and facilitating large-scale manufacture through wafer-level processes.
Implementation Method 1
the material of the first micro-spacers partially is cured prior to forming the second micro-spacers on the second optical element layer
Data Source
AI summary
The present disclosure describes optical and optoelectronic assemblies that, in some cases, include screen-printed micro-spacers, as well as methods for manufacturing such assemblies and modules. For example, an optoelectronic device mounted on a substrate can include an optical sub-assembly including a first optical element and a first micro-spacer on the optical element. The optical sub-assembly can be disposed over the optoelectronic device, with a first air or vacuum gap separating the first optical element from the optoelectronic device, and the first micro-spacer laterally surrounding the first air or vacuum gap.