Micro-lens Array Alignment Marks Reduce Manufacturing Time
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Solution Overview
Problem
The existing manufacturing methods for micro-lens arrays are time-consuming due to the need for multiple alignment steps and complex substrate configurations, which increase manufacturing costs and complicate the overall structure of vehicle lamps.
Innovation Solution
A micro-lens array structure and manufacturing method that includes a shutter bezel substrate with a photoresist layer, bonded lens substrates, and alignment marks to guide placement, allowing for reduced alignment times by cutting substrate assemblies with overlapping mother substrates and forming lens arrays on both surfaces, thereby minimizing the number of alignment steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple alignment steps are used to ensure precise lens array placement, then manufacturing precision is improved, but manufacturing time increases
Solution Approach 1:
Alignment marks are pre-defined on the lens substrate before lens array placement, enabling quick visual alignment without requiring multiple complex alignment steps. This preliminary preparation of reference markers resolves the contradiction by providing immediate alignment guidance that maintains precision while reducing time.
Solution Approach 2:
The alignment marks serve as simplified copies or references of the desired final configuration, allowing operators to quickly replicate the correct positioning without performing multiple iterative alignment operations. This copying approach maintains precision through reference fidelity while dramatically reducing the time required for alignment.
2Reliability
If complex substrate configurations are used to achieve precise light distribution, then lighting function is improved, but device complexity increases
Solution Approach 1:
The substrate is divided into functional regions: a shutter bezel substrate for structural support and light blocking, and a separate lens substrate for optical functions. This segmentation allows each component to be optimized independently, maintaining reliable lighting functions while reducing overall configuration complexity through modular design.
Solution Approach 2:
The lens substrate serves multiple functions: it provides the mechanical base for lens array mounting, defines alignment through pre-defined marks, and contributes to the overall light distribution structure. This multi-functionality reduces the need for separate dedicated components, thereby simplifying the overall device complexity while maintaining lighting reliability.
3Manufacturing precision
If multiple substrate assemblies are manufactured separately, then manufacturing precision is improved, but productivity decreases
Solution Approach 1:
Multiple substrate assemblies are manufactured by bonding lens substrates to a central shutter bezel substrate in a single integrated process, rather than producing separate assemblies that would later be combined. This merging approach maintains precision through unified alignment references while significantly improving productivity by reducing the number of discrete manufacturing steps.
Solution Approach 2:
The shutter bezel substrate is prepared in advance with designated bonding areas and alignment references, enabling multiple lens substrates to be attached simultaneously or in rapid sequence. This preliminary preparation of the central substrate creates a hub-and-spoke manufacturing approach that maintains precision through pre-established references while boosting productivity through parallel processing capability.
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 significantly reduces the manufacturing time of micro-lens arrays by minimizing the number of alignment steps and enabling the production of substrate assemblies in a shorter time, thereby lowering costs and simplifying the manufacturing process.
Implementation Method 1
a photoresist layer attached to at least one surface of the shutter bezel substrate
Implementation Method 2
an alignment mark that is configured to guide placement of the first lens array on the first lens substrate and the second lens array on the second lens substrate
Data Source
AI summary
A micro-lens array includes a shutter bezel substrate, a first lens substrate having a first inner surface in contact with a first surface of the shutter bezel substrate, a first lens array disposed at a first outer surface of the first lens substrate that is opposite to the first inner surface of the first lens substrate, a second lens substrate having a second inner surface in contact with a second surface of the shutter bezel substrate, and a second lens array disposed at a second outer surface of the second lens substrate that is opposite to the second inner surface of the second lens substrate. At least one of the first lens substrate or the second lens substrate includes an alignment mark that is configured to guide placement of the first lens array on the first lens substrate and the second lens array on the second lens substrate.