Integrated Optical Element Fabrication With Molded Lens Coatings
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Solution Overview
Problem
Existing methods for fabricating optical elements, particularly for spectrometer devices, are costly and inefficient, requiring multiple assembly steps that can lead to manufacturing defects.
Innovation Solution
A method involving substrate preparation, deposition of optical filters and anti-reflection coatings, and injection molding of lenses onto these layers, allowing for automated fabrication without manual steps and enabling high-volume, scalable production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional lithography and etching processes are used to fabricate aspheric optical elements, then manufacturing precision can be achieved, but device complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent replaces complex mechanical lithography and etching processes with a direct spin-coating method using photoresist material. Instead of using sophisticated lithography equipment to pattern the substrate, the invention applies photoresist material directly onto the substrate through spin-coating, forming the desired aspheric profile in a single step, thereby substituting complex mechanical systems with a simpler material-based approach
Solution Approach 2:
The invention changes the physical and chemical parameters of the photoresist material through controlled heating and curing processes. By adjusting temperature parameters during spin-coating and subsequent curing steps, the photoresist material transforms from a liquid state to a solidified aspheric optical element, achieving precise shape control through parameter optimization rather than complex mechanical machining
2Manufacturing precision
If multiple lithography and etching steps are employed to achieve desired optical profiles, then manufacturing precision improves, but productivity decreases
Solution Approach 1:
The patent merges multiple separate lithography and etching operations into a single spin-coating process. By combining the functions of pattern formation, material deposition, and profile creation into one integrated spin-coating step using specially formulated photoresist material, the invention eliminates the need for sequential processing steps, thereby maintaining manufacturing precision while significantly improving production throughput
Solution Approach 2:
The invention performs preliminary action by pre-formulating the photoresist material with specific rheological properties and optical characteristics that enable it to self-organize into the desired aspheric profile during spin-coating. This preliminary material preparation eliminates the need for subsequent etching and machining steps, as the final optical profile is achieved directly during the spin-coating process itself
3Manufacturing precision
If traditional manufacturing methods are used for optical elements, then manufacturing precision can be maintained, but ease of manufacture deteriorates
Solution Approach 1:
The patent replaces traditional mechanical manufacturing methods (lithography, etching, machining) with a chemical-material based spin-coating process. This substitution simplifies the manufacturing workflow by using a single-step material deposition technique that inherently produces the desired aspheric optical profile, making the manufacturing process easier to execute while maintaining high precision through material property control
Solution Approach 2:
The photoresist material exhibits self-organizing properties during the spin-coating process, automatically forming the desired aspheric optical profile without requiring complex external guidance or multiple processing steps. The material's inherent rheological and optical properties enable it to self-structure into the correct geometry, reducing the need for sophisticated manufacturing equipment and complex process 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
Facilitates cost-effective and efficient fabrication of optical elements with integrated components, ensuring correct alignment and reducing assembly costs while enabling large-scale production.
Implementation Method 1
heating the photoresist material to a temperature between a glass transition temperature of the photoresist material and a decomposition temperature of the photoresist material
Implementation Method 2
spinning the substrate while in the spin coater, heating the photoresist material
Data Source
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AI summary
A method of fabricating at least one optical element (110), specifically at least one optical element (110) for a spectrometer device, is disclosed. The method comprises: i. at least one preparation step, wherein the preparation step comprises providing at least one substrate (112) having at least one first surface (116) and at least one second surface (118), wherein the second surface (118) is located opposite with respect to the first surface (116); ii. at least one deposition step, wherein the deposition step comprises applying at least one first layer (124) to the first surface (116) of the substrate (112), wherein the first layer (124) comprises at least one of an optical filter (126) and an anti-reflection coating (128); and iii. at least one molding step, wherein the molding step comprises molding at least one optical lens (132) onto the first layer (124). Further disclosed is a system (152) for fabricating at least one optical element (110) and an optical element (110).