Micro-optics Alignment Using Needle Pin and Temporary Attachment
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Solution Overview
Problem
Conventional methods for aligning micro-optical components are inefficient due to the size constraints and risk of damage, as manual tools like tweezers or vacuum tweezers can't handle small components without blocking light paths or causing scratches, necessitating a new approach for precise alignment and assembly.
Innovation Solution
A needle pin attached to an optical component allows for precise alignment within a limited space, using a mechanical extension arm with 6 degrees of freedom, enabling temporary adhesive mounting and subsequent permanent bonding to a substrate, with the needle pin detachable without damaging the component or affecting the optical path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional tools like tweezers or vacuum tweezers are used to hold optical components, then the components can be manipulated, but the tools block the optical light path and may damage or scratch the optical surfaces
Solution Approach 1:
The holding function is segmented from the manipulation tool. A needle pin serves as the holding tool while a separate mechanical extension arm with translation stage performs positioning and alignment operations. This segmentation allows the holding tool to be minimal and non-intrusive to the optical path.
Solution Approach 2:
The needle pin acts as an intermediary holding tool that attaches to the optical component without blocking the optical path. The mechanical extension arm serves as an intermediary positioning system that manipulates the needle pin-component assembly without direct contact with the optical surfaces.
2Volume of moving object
If the size of optical components is reduced to millimeters or sub-millimeters, then device integration is improved, but conventional holding tools become larger than the component cross sections and cannot handle them properly
Solution Approach 1:
The holding system is segmented into a minimal needle pin attachment point and a remote mechanical manipulation system. The needle pin provides a small attachment footprint suitable for millimeter-scale components, while the extension arm provides the manipulation capability without size constraints.
Solution Approach 2:
The manipulation system transitions from direct 2D planar handling to 3D spatial manipulation using a mechanical extension arm with translation stages. This allows positioning and alignment in three dimensions, enabling proper handling of small components regardless of their cross-sectional size.
3Object-affected harmful factors
If optical surfaces are not touched to avoid damage, then surface integrity is maintained, but the holding area of the optical component is further constrained
Solution Approach 1:
The holding function is separated from the optical surfaces. The needle pin attaches to non-optical areas or edges of the component, while the mechanical extension arm performs all manipulation operations without contact with the optical surfaces, maintaining surface integrity while providing adequate holding capability.
Solution Approach 2:
The needle pin serves as an intermediary attachment point that does not compromise optical surfaces. The mechanical extension arm acts as an intermediary manipulation tool that handles the component without touching the optical surfaces, thus preventing damage while maintaining full holding control.
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
Enables precise and damage-free alignment and assembly of small optical components, reducing assembly time and costs while ensuring optimal optical system performance by allowing controlled XYZ translation and angular adjustments.
Implementation Method 1
temporarily mounted to the needle pin by adhesive
Implementation Method 2
bonding the optical component to the location permanently with a type of adhesive
Data Source
AI summary
Techniques for micro-optics alignment and assembly are described. By attaching a needle pin to an optical component to be assembled, the optical component can be placed and aligned within a limited space. After the aligned optical component is permanently bonded to a substrate or to another component, the needle pin is detached from the component. This technique allows a user to place and align a small optical component to a right position.