Multi-layer Polymer Lens with Non-planar Cavity for Optical Control

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Molded lenses used in mobile devices face challenges in maintaining quality and achieving diverse optical performance due to difficulties in forming multiple molds with exact dimensions and the limitations of monolithic lenses, leading to declining quality over time and increased cost with larger sizes.

Innovation Solution

A multi-layered lens is created using a substrate formed of discrete polymer layers with non-planar cavity surfaces, achieved through a process involving polymer deposition, photo-lithography, and isotropic etching, allowing for precise control of optical properties and stacking of lenses for enhanced performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If molded lenses are used for mass production, then productivity is improved, but manufacturing precision deteriorates due to difficulty in forming multiple molds with exactly the same dimensions

Engineering Contradiction:

Improvemass production capabilityVSAvoiddimensional consistency

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The lens is divided into multiple discrete polymer layers (first polymer layer, second polymer layer, etc.) that are formed separately and then bonded together. Each layer can be independently manufactured with precise control, avoiding the dimensional consistency issues of traditional single-piece molded lenses while maintaining mass production capability through sequential layer formation.

Inventive Principle:

Principle #1Segmentation

2Ease of manufacture

If monolithic molded lenses are used, then ease of manufacture is improved, but adaptability deteriorates due to limited optical properties

Engineering Contradiction:

Improvemolding process simplicityVSAvoidoptical properties diversity

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The lens is constructed as a composite structure with multiple polymer layers, where each layer can have different materials, refractive indices, and optical properties. This allows diverse optical performance to be achieved by combining layers with complementary characteristics, overcoming the limitations of single-material monolithic lenses.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

Different regions of the lens are created with different optical properties by varying the polymer layer composition, thickness, and cavity structures in specific zones. This enables localized optimization of optical characteristics such as refraction, reflection, and focusing in different parts of the lens.

Inventive Principle:

Principle #3Local quality

3Adaptability or versatility

If multiple monolithic lenses are stacked to achieve diverse optical properties, then adaptability is improved, but device complexity increases

Engineering Contradiction:

Improveoptical properties diversityVSAvoidstacked lens structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

Multiple functional layers are merged into a single integrated multi-layer lens structure through bonding. Instead of stacking separate monolithic lenses, the different optical functions are combined within one unified multi-layer component, reducing overall device complexity while maintaining diverse optical capabilities.

Inventive Principle:

Principle #5Merging (Combining)

4Ease of manufacture

If molded lenses are used, then ease of manufacture is improved, but reliability deteriorates due to mold fatigue over time

Engineering Contradiction:

Improvemolding processVSAvoidlens quality consistency

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The lens structure is designed with pre-formed polymer layers and cavities that are created before final assembly. This preliminary formation of layers with precise dimensions and optical properties eliminates the need for repeated high-precision molding operations, reducing mold fatigue and ensuring consistent quality over time.

Inventive Principle:

Principle #10Preliminary action

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

The multi-layered lens design provides superior quality, uniformity, and diverse optical performance without significant cost increases, enabling precise control of optical focusing and improved light handling capabilities.

Implementation Method 1

Lenses are often made of glass or polymer, and are typically made using a molding process... The light sensor converts the incoming light into electronic signals that represent the image formed by the incoming light

Methodology Applied

Scientific EffectRefraction: Refraction

Data Source

PatentUS8570669B2Multi-layer polymer lens and method of making same

Publication Date: 2013.10.29 OPTIZ

AI summary

A multi-layered lens having a substrate with opposing first and second surfaces. The substrate is formed of a plurality of discrete polymer layers. A cavity is formed into the first surface and is defined by a non-planar cavity surface that acts as a lens surface. The cavity extends into and exposes each of the plurality of polymer layers. The compositions of the polymer layers can vary to provide optimized focal properties. Alignment marks in the form of cavities or protrusions can be formed at the first surface or the second surface, so that multiple lenses can be stacked together in an aligned manner to form a stacked lens assembly.