Optical System Alignment via Pre-Formed Substrate Features
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Solution Overview
Problem
Achieving and maintaining proper alignment between optical components in complex optical systems is a manufacturing challenge, particularly when tolerances are as low as 50 microns or less.
Innovation Solution
A method for manufacturing optical systems involves coupling substrates with light-emitter devices and optical lenses, using a second substrate with a mounting surface and optical spacer, and applying adhesive materials to ensure precise alignment, utilizing cameras for alignment features and a vacuum chuck for positioning, with spring structures to exert restoring forces for accurate placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing methods are used for optical systems, then manufacturing process is simpler, but alignment precision between optical components deteriorates
Solution Approach 1:
The patent applies preliminary action by pre-forming alignment features (such as recesses, protrusions, or fiducial marks) on the substrates before the actual assembly process. This allows the components to self-align during bonding, ensuring precise alignment without requiring complex real-time adjustment mechanisms during manufacturing.
Solution Approach 2:
The patent introduces intermediary alignment features and alignment layers that mediate between the optical components and substrates. These intermediaries provide reference surfaces and geometric constraints that facilitate precise alignment, acting as a bridge between components that would otherwise be difficult to align directly.
2Reliability
If tight alignment tolerances (50 microns or less) are required, then optical system performance is improved, but manufacturing difficulty increases
Solution Approach 1:
The patent changes geometric parameters of the alignment features, such as the size and shape of recesses, protrusions, or bonding areas, to provide inherent alignment constraints. By carefully designing these parameters, the system achieves tight alignment tolerances through geometric constraints rather than relying solely on high-precision positioning equipment.
Solution Approach 2:
The patent segments the alignment function into separate alignment features and bonding features. This segmentation allows the alignment function to be optimized independently through specialized geometric features, while the bonding function is handled separately through adhesive materials, making the overall manufacturing process more manageable despite tight tolerances.
3Adaptability or versatility
If multiple optical components are assembled, then optical system functionality is improved, but maintaining alignment between components becomes more difficult
Solution Approach 1:
The patent designs universal alignment features and reference structures that can be used across multiple components and assembly steps. These universal features provide consistent alignment references throughout the assembly process, allowing multiple optical components to be assembled while maintaining alignment through a common reference framework.
Solution Approach 2:
The patent merges multiple alignment functions into integrated alignment structures that simultaneously provide positioning, orientation, and spacing for multiple components. By combining these functions into single structural elements, the system maintains alignment across multiple components without requiring separate alignment mechanisms for each component pair.
Data Source
AI summary
Systems and methods described herein relate to the manufacture of optical elements and optical systems. An example method includes providing a first substrate that has a plurality of light-emitter devices disposed on a first surface. The method includes providing a second substrate that has a mounting surface defining a reference plane. The method includes forming a structure and an optical spacer on the mounting surface of the second substrate. The method additionally includes coupling the first and second substrates together such that the first surface of the first substrate faces the mounting surface of the second substrate at an angle with respect to the reference plane.