Optical Computing Device Stereolithography Manufacturing

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Solution Overview

Problem

In optical computing devices, maintaining planar light diffraction elements in a desired relative positional relation is challenging due to deviations, which can hinder desired optical computations and increase power consumption.

Innovation Solution

A method involving a container with optically-transparent side and bottom walls, filled with a photo-curable resin, where stereolithography is used to form light diffraction elements on the bottom walls, ensuring precise positioning and alignment of light diffraction units through the formation of cavities and controlled curing of the resin.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional methods are used to manufacture optical computing devices, then light diffraction elements can be produced, but maintaining desired relative positional relation between elements is difficult and deviations occur

Engineering Contradiction:

Improverelative positional relationVSAvoidmanufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The invention divides the manufacturing process into separate steps: first forming the container structure with bottom walls, then filling with photo-curable resin, and finally performing stereolithography to form light diffraction elements. This segmentation allows precise control of positional relations between elements during the curing process.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The container with bottom walls is formed in advance before filling with photo-curable resin. This preliminary structure provides a precise framework that guides the formation of light diffraction elements at desired positions, ensuring accurate relative positional relations before the elements are fully cured.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If light diffraction elements are arrayed to perform optical computation, then computational functionality is achieved, but nm-order deviations in relative positional relation prevent desired optical computation

Engineering Contradiction:

Improveoptical computation accuracyVSAvoidrelative positional relation

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The invention replaces conventional mechanical positioning methods with stereolithography-based precision positioning. By using photopolymerization processes guided by predetermined patterns, the system achieves nm-order precision in element positioning without complex mechanical alignment procedures.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention utilizes changes in material state through photopolymerization, where photo-curable resin transitions from liquid to solid upon light irradiation. This parameter change enables precise dimensional control and maintains nm-order positional accuracy during the formation of light diffraction elements.

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If multiple light diffraction units are layered, then optical computation functionality is enhanced, but maintaining desired relative positional relation between units becomes increasingly difficult

Engineering Contradiction:

Improveoptical computation functionalityVSAvoidrelative positional relation

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The invention employs a nested structure where multiple containers with light diffraction elements are layered within a larger assembly framework. Each container maintains its own internal precision while the nested arrangement ensures consistent relative positional relations between different light diffraction units through the shared bottom wall structure.

Inventive Principle:

Principle #7Nested doll (Nesting)

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 allows for easy maintenance of light diffraction elements in a desired relative positional relation, enhancing the accuracy and efficiency of optical computations while reducing power consumption.

Implementation Method 1

carrying out stereolithography by emitting light to a part near an interface between the bottom wall WBi and the liquid material Ri to cure the photo-curable resin

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Data Source

PatentUS20230417963A1Method for manufacturing optical computation device, optical diffraction unit intermediate, and optical computation device

Publication Date: 2023.12.28 FUJIKURA LTD

AI summary

A method is provided for manufacturing an optical computing device using a container that includes n side walls WS1 to WSn and n bottom walls WB1 to WBn made of an optically-transparent material, where n is a natural number of not less than 2. The method includes: forming the container including an i-th cavity Ci, using at least an i-th bottom wall WBi and an i-th side wall WSi, where i is an integer of 1≤i≤n; filling the cavity Ci with a liquid material Ri containing a photo-curable resin; and forming a light diffraction element on one main surface of the bottom wall WBi through stereolithography by emitting light to a part near an interface between the bottom wall WBi and the liquid material Ri to cure the photo-curable resin.