Optical Coupler Manufacturing with Scattering Filler
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Solution Overview
Problem
The use of grayscale masks in manufacturing optical couplers leads to light diffraction, resulting in high levels of diffracted light being emitted in directions other than the intended, which decreases processing accuracy.
Innovation Solution
A method of manufacturing optical couplers that involves using a light-transmitting substrate with a first photosensitive glass paste containing a filler, where the filler's longest length is greater than the ultraviolet ray wavelength, to scatter diffracted light and maintain intended light exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a grayscale mask is used in manufacturing optical couplers, then the light transmittance can be controlled according to area ratio, but light diffraction occurs and processing accuracy decreases
Solution Approach 1:
A light-transmitting substrate is introduced as an intermediary component between the grayscale mask and the photosensitive material. This substrate contains scattering particles that mediate the light path, scattering diffracted light to prevent it from reaching the photosensitive material, thereby resolving the contradiction between ease of manufacture and manufacturing precision
Solution Approach 2:
The invention converts the harmful diffracted light into a beneficial effect by using scattering particles to redirect it. The diffracted light that would normally cause processing errors is scattered by the particles in the light-transmitting substrate, converting a harmful phenomenon into a controlled optical path modification that protects processing accuracy
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 effectively suppresses the decrease in processing accuracy by scattering diffracted light, ensuring that the photosensitive material is exposed as designed.
Implementation Method 1
In a case where the longest length of the first filler is larger than the wavelength of the ultraviolet ray, the ultraviolet ray diffracted by the grayscale mask is scattered by the first filler.
Implementation Method 2
light is diffracted during exposure by the periodic structure of the light-transmitting region and the light-shielding region
Implementation Method 3
emitting an ultraviolet ray to the second main surface to expose the first photosensitive glass paste
Data Source
AI summary
A method of manufacturing an optical coupler that includes: preparing a light-transmitting substrate having a first main surface and a second main surface aligned in a first direction; applying a first photosensitive glass paste containing a first filler to the first main surface; arranging a grayscale mask formed in a binary pattern on the second main surface; emitting an ultraviolet ray to the second main surface to expose the first photosensitive glass paste; removing the grayscale mask from the second main surface and developing the first photosensitive glass paste; and removing the light-transmitting substrate from the first photosensitive glass paste developed and curing the first photosensitive glass paste, wherein a longest length of the first filler is larger than a wavelength of the ultraviolet ray.