Optical Component Carrier Structure for Batch Transfer Mounting
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Solution Overview
Problem
Existing methods for attaching optical components to devices are time-consuming and costly due to the labor-intensive process of individually mounting multiple components.
Innovation Solution
A method involving the use of an intermediate carrier with a sacrificial layer and retaining structure allows for the production of detachable optical components, which can be printed in groups and transferred to target surfaces efficiently, using a stamp or stamps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If optical components are individually attached to devices, then mounting reliability is improved, but production time and costs increase
Solution Approach 1:
The patent segments the mounting process into two distinct phases: (1) batch formation of optical components on an intermediate carrier with retaining structures, and (2) group transfer to target devices. This segmentation allows individual component precision during formation while enabling efficient group handling during transfer, resolving the contradiction between reliable individual mounting and fast production.
Solution Approach 2:
The patent applies preliminary action by pre-forming multiple optical components on a common intermediate carrier with retaining structures before transfer. The retaining structures are pre-configured to mechanically connect components to the carrier, ensuring stable positioning during transport and enabling subsequent group detachment and transfer to multiple devices simultaneously, thus improving productivity without sacrificing mounting reliability.
2Stability of the object's composition
If optical components are securely fixed during transport, then component stability is improved, but ease of detachment for transfer deteriorates
Solution Approach 1:
The patent employs dynamic characteristics through retaining structures with breakable connections that exhibit state-dependent behavior: strong mechanical connection during transport to ensure stability, and controlled detachment when release force is applied during transfer. This dynamic transition from fixed to detached state resolves the contradiction between stable positioning and easy transfer.
Solution Approach 2:
The patent changes the connection parameter from strongly bound to easily detachable by applying release force to break the mechanical connection of the retaining structures. This parameter change enables the system to transition between stable transport mode and easy transfer mode, resolving the contradiction between component stability and ease of detachment.
3Productivity
If multiple optical components are produced on a common carrier, then productivity is improved, but device complexity increases
Solution Approach 1:
The patent segments the carrier structure into functional modules: an intermediate carrier for batch production, retaining structures for mechanical connection, and breakable connections for controlled release. This modular segmentation manages complexity by organizing complex functions into distinct, manageable components while enabling high productivity through batch processing.
Solution Approach 2:
The intermediate carrier acts as an intermediary element that temporarily holds multiple optical components during production and transfer. This intermediary structure enables batch processing and group transfer without requiring complex individual handling mechanisms, thus improving productivity while managing complexity through a dedicated intermediate structure that can be removed after transfer.
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 quick, reliable, and cost-effective mounting of optical components by ensuring they are securely held during transport and easily detachable for transfer, reducing production time and costs.
Implementation Method 1
The material of the sacrificial layer is chosen such that it can be dissolved by an etching process without damaging the intermediate carrier and/or the optical components
Data Source
AI summary
A composite component, a device, and method for producing the composite component including a plurality of optical components, a removable sacrificial layer, a retaining structure and a common intermediate carrier are provided, wherein the optical components each have an optical element for shaping a light beam and the sacrificial layer is arranged in the vertical direction at least in places between the intermediate carrier and the optical components. The retaining structure includes retaining elements, wherein the retaining structure and the sacrificial layer form a mechanical connection between the intermediate carrier and the optical components. The optical components are mechanically connected to the intermediate carrier only via the retaining structure, wherein the retaining elements are formed in such a way that under mechanical load they release the optical components so that the optical components are formed to be detachable from the intermediate carrier and thus transferable.