Microlens Embossing with Segmented Curing and Die Control
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Solution Overview
Problem
The miniaturization of microlenses for optical focusing devices poses challenges in maintaining high fidelity of shape and precise optical axis alignment due to shrinkage and cumulative faults during the curing process, especially in mass production, where the thickness and number of optics along the optical axis affect the beam path and resolution.
Innovation Solution
A method and device that emboss and cure microlenses simultaneously, allowing for spatial separation and active force-regulated die control to maintain shape fidelity and optical axis alignment, compensating for shrinkage by adjusting the distance between dies during curing, and using separate lens molds to prevent cumulative faults.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If microlenses are produced by conventional embossing and curing methods, then mass production is achieved, but shape fidelity deteriorates due to shrinkage and cumulative faults
Solution Approach 1:
The patent divides the microlens array into individually separated microlenses during the embossing process. Each microlens is embossed and cured separately rather than as a continuous array, preventing cumulative shrinkage faults across the entire array. This segmentation allows independent control of each microlens geometry while maintaining mass production efficiency.
Solution Approach 2:
The patent applies preliminary separation of lens material portions before curing occurs. By creating physical separation between adjacent microlenses during embossing (while the material is still moldable), the system prevents cumulative shrinkage effects that would occur if all microlenses were cured together as a continuous structure.
2Productivity
If microlenses are cured together as a continuous array, then production efficiency is maintained, but optical axis alignment deteriorates due to wedge faults
Solution Approach 1:
The patent segments the continuous lens material into individually separated microlenses during embossing, allowing each microlens to be cured independently. This eliminates wedge faults that would propagate across a continuous array, ensuring each optical axis is perpendicular to the carrier substrate without cumulative alignment errors.
Solution Approach 2:
The patent implements active force-regulated die control that monitors and adjusts the embossing force in real-time during the curing process. This feedback mechanism compensates for material shrinkage and maintains precise optical axis alignment throughout curing, preventing wedge faults while maintaining production efficiency.
3Manufacturing precision
If separate separation steps are used to divide microlenses, then shape fidelity can be maintained, but production complexity increases
Solution Approach 1:
The patent merges the separation and curing operations into a single integrated process step. The microlenses are separated during embossing and then cured in place without requiring additional separation steps, reducing process complexity while maintaining shape fidelity through the preliminary separation of lens material portions.
Solution Approach 2:
The separation of microlenses is performed preliminarily during the embossing stage before curing occurs. This preliminary action eliminates the need for subsequent separation steps, as the microlenses are already physically separated and can be cured independently in their final positions.
4Device complexity
If the die distance is fixed during curing, then device simplicity is maintained, but shape fidelity deteriorates due to uncontrolled shrinkage
Solution Approach 1:
The patent transforms the fixed die distance into a dynamic, actively controllable parameter. The distance between the first and second dies is adjusted in real-time during curing based on feedback from force sensors, allowing the system to compensate for material shrinkage and maintain precise microlens geometry throughout the curing process.
Solution Approach 2:
The patent implements feedback control where force sensors monitor the embossing force during curing, and this information is used to actively adjust the die distance. This closed-loop control compensates for material shrinkage in real-time, maintaining shape fidelity without requiring overly complex predetermined mechanisms.
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 high-precision mass production of microlenses with improved shape fidelity and optical axis alignment, reducing the need for separate separation steps and ensuring consistent optical quality by controlling shrinkage and wedge faults, thus enhancing the contour accuracy and brilliance of the microlenses.
Implementation Method 1
a curable fluid, preferably polymer, in fluid form is applied separately for each microlens to be produced to a respective first lens mold
Implementation Method 2
the microlens shrinks, and therefore a differential volume arises between the die and the microlens
Data Source
AI summary
Device and method for producing a plurality of microlenses from a lens material. The method includes: applying lens material intended for the embossing of the microlenses to a plurality of first lens molds distributed on a first embossing side of a first die for embossing of the microlenses, moving the first die and a second die located essentially parallel, in an X-Y plane, and opposite the first die, on top of one another in a Z-direction running essentially perpendicular to the X-Y plane, embossing the microlenses by shaping and curing the lens material, the shaping taking place by moving the first and second embossing sides on top of one another, up to a thickness D1 of the lens material in the Z-direction, wherein the lens material of each microlens at least during curing is separate from the lens material of each microlens which is adjacent in the X-Y plane.