Multi-sided Prism Printing via Angled Stencil Alignment
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Solution Overview
Problem
Conventional methods for printing patterns on prisms are inefficient and inaccurate, particularly when trying to align patterns on multiple lateral faces simultaneously, which affects the optical performance of small form factor cameras.
Innovation Solution
The development of multi-sided prism printing systems and methods that apply a light-blocking material, such as a polymer, to two or more sides of prisms simultaneously using stencil printing or photolithography processes, allowing for accurate alignment and increased throughput by using angled stencils and curing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional one-side-at-a-time printing methods are used, then manufacturing complexity is reduced, but productivity decreases and manufacturing precision deteriorates
Solution Approach 1:
The patent combines multiple printing operations into a single simultaneous process. The printing system applies light-blocking material to multiple lateral faces of prisms at the same time using multiple nozzles or a multi-sided printing head, rather than printing one face sequentially. This merging of operations directly increases throughput while the coordinated control system manages the added complexity.
Solution Approach 2:
The patent transitions from one-dimensional sequential printing (one face at a time) to multi-dimensional simultaneous printing. By arranging printing nozzles to access multiple faces of prisms concurrently from different angles, the system achieves parallel processing across multiple dimensions, significantly improving productivity.
2Manufacturing precision
If conventional one-side-at-a-time printing methods are used, then device complexity is reduced, but manufacturing precision deteriorates
Solution Approach 1:
The patent incorporates feedback mechanisms to ensure precise pattern alignment when printing multiple faces simultaneously. Sensors detect the position and orientation of prisms, and the control system adjusts nozzle positions and printing parameters in real-time based on this feedback, maintaining high manufacturing precision despite the complexity of multi-sided simultaneous printing.
Solution Approach 2:
The patent replaces mechanical alignment methods with optical or computational approaches. Instead of physically positioning and repositioning prisms for each face, the system uses optical sensors, vision systems, or computational algorithms to determine prism orientations and calculate precise printing paths, achieving high alignment accuracy more efficiently.
3Manufacturing precision
If photoimageable polymer and photolithography processes are used, then manufacturing precision is improved, but loss of time increases due to additional process steps
Solution Approach 1:
The patent applies preliminary actions to reduce total process time. The prism bar is pre-positioned on a substrate with multiple faces accessible, and the light-blocking material is applied to multiple faces simultaneously before any patterning occurs. This preliminary multi-face coating eliminates the need for repeated positioning and processing cycles, reducing time loss despite using photolithography.
Solution Approach 2:
The patent maintains continuity of useful action throughout the process. By keeping the prism bar in a fixed position on the substrate and continuously applying material to multiple faces without removing and repositioning the prisms, the system eliminates idle time between operations. The photolithography exposure and development processes then proceed continuously on all faces simultaneously.
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 enhances the alignment and efficiency of pattern printing on prisms, enabling the production of compact optical systems for small form factor cameras that capture high-resolution images while reducing the camera's size, making them suitable for mobile devices.
Implementation Method 1
An exposure process is then applied to cure the photoimageable polymer on the exposed surfaces of the prisms through the 2D stencil to pattern the first and third lateral faces of the prisms
Data Source
AI summary
Multi-sided prism printing systems and processes that apply a light-blocking material (e.g., a polymer) to at least part of the surfaces of at least two sides of a prism at the same time. The multi-sided prism printing systems and processes may significantly increase throughput of prism printing when compared to conventional prism printing methods in which only one side of a prism is printed at a time. In addition, the multi-sided prism printing systems and processes may provide a more accurate alignment of the printed patterns on lateral faces of the prism when compared to conventional prism printing methods in which only one lateral face of a prism is printed at a time.