Microlens Aperture Layer Alignment Using Photosensitive Hole Formation
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Solution Overview
Problem
The manufacturing of optical systems with a layer of apertures and micrometric-sized optical elements is hindered by the need for costly alignment tools and the challenge of maintaining precise alignment due to thermal and mechanical deformations, limiting scalability and precision.
Innovation Solution
A method using a photosensitive resin layer that forms holes upon exposure to specific radiation, allowing for the alignment and assembly of micrometric-sized optical elements without the need for precise alignment tools, enabling reel-to-reel manufacturing and improved scalability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If alignment tools are used to position micrometric-sized optical elements relative to the aperture layer, then positioning precision is improved, but manufacturing cost increases and large-scale production is not enabled
Solution Approach 1:
The patent applies preliminary action by pre-forming alignment marks and reference structures on the aperture layer before arriving the microlens array. This allows the microlenses to be positioned relative to pre-existing references rather than requiring complex real-time alignment tools during assembly, thereby reducing manufacturing cost while maintaining positioning precision
Solution Approach 2:
The patent implements self-service through self-alignment mechanisms where the microlens array and aperture layer automatically align via pre-formed reference structures, alignment marks, or complementary geometric features. This eliminates the need for expensive external alignment tools and enables large-scale automated production while maintaining precise positioning
2Ease of manufacture
If organic materials are used for the aperture layer and/or micrometric-sized optical elements, then ease of manufacture is improved, but thermal and mechanical deformations occur that prevent correct alignment
Solution Approach 1:
The patent applies beforehand cushioning by incorporating compensation features in the design of the aperture layer and microlens array that anticipate and counteract thermal and mechanical deformations. This may include expansion compensation structures, stress-relief designs, or temperature-stable reference markers that maintain alignment precision despite material deformations
Solution Approach 2:
The patent uses parameter changes by selecting and optimizing material parameters (such as thermal expansion coefficients, modulus of elasticity) and structural parameters (such as layer thickness, geometry) to minimize the impact of thermal and mechanical deformations on alignment precision, thereby maintaining both ease of manufacture and alignment accuracy
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 achieves precise positioning of optical elements relative to apertures, facilitating industrial-scale production of optical systems with enhanced precision and reduced costs, while maintaining optical system functionality.
Implementation Method 1
the film is made of a resin that is photosensitive to the second radiation
Data Source
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AI summary
The present description relates to a process for manufacturing an optical system (5) comprising a layer (24) comprising through- or blind holes (26) and covered with a matrix array of optical elements (14) of micrometric size. The optical system comprises a face (22) intended to receive a first emission. The process comprises exposing a film (24), of the same material as the layer or of a material different from that of the layer, to a second emission through the matrix array of optical elements (14) of micrometric size, said material being photosensitive to the second emission or machinable using the second emission, and removing the portions of the film exposed or not exposed to the second emission in order to define holes (26) that pass right or someway through said layer.