Optical Filter Assembly With Capillary Resin Frame Filling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing optical filter assemblies are complex, expensive, and require post-processing steps, such as grinding or chemical-mechanical thinning, which can lead to staining or overflow of light blocking materials, affecting the accuracy and quality of the filter assembly.
Innovation Solution
A method involving a mold with a predefined pattern and capillary filling of a light blocking resin to form a filter frame, where optical filters are arranged in a predetermined array, allowing for uniform distribution of the resin without overflow, and a transparent finish layer is applied to protect the filter coatings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If post-processing steps (grinding or chemical-mechanical thinning) are used to remove excess resin, then the filter assembly can be manufactured, but staining or overflow of light blocking materials occurs affecting accuracy and quality
Solution Approach 1:
The mold cavity is designed with a bottom that defines a predetermined depth, establishing the final thickness of the filter assembly before the resin curing process begins. This preliminary action prevents the need for post-processing removal steps, eliminating staining and overflow issues that affect measurement accuracy.
Solution Approach 2:
The mold design incorporates a defined bottom surface that preemptively counteracts the potential harmful effect of excess resin accumulation. By pre-establishing the depth boundary, the system prevents staining and overflow from occurring in the first place, rather than correcting them afterward.
2Measurement precision
If complex optical designs with multiple optical components are used in spectrometers, then detailed wavelength information can be determined, but the device becomes expensive and large
Solution Approach 1:
Multiple optical filters with different spectral sensitivities are arranged in an array within a single filter assembly, combining their functions into one integrated component. This merging approach maintains the ability to determine detailed wavelength information while reducing overall device complexity and size compared to traditional spectrometer designs.
Solution Approach 2:
The filter assembly is segmented into multiple individual filters arranged in an array, each handling specific wavelength ranges. This segmentation allows the system to achieve detailed spectral analysis capabilities without requiring a single complex optical path, thereby reducing device size and cost.
3Measurement precision
If sensor filters are optimized to account for filtering by other optical components, then each sensor can provide accurate signals, but the sensor filters become complex and expensive
Solution Approach 1:
The filter assembly integrates multiple filters with different spectral sensitivities into a single structured array, combining the functions of what would otherwise require multiple optimized sensor filters. This approach maintains measurement precision while reducing the complexity and cost associated with individually optimizing each sensor filter.
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 method enables accurate spectral analysis by preventing contamination between filters, ensuring uniform resin distribution, and maintaining the optical performance of the filter assembly without post-processing, thus enhancing the quality and efficiency of the multichannel optical sensor.
Implementation Method 1
resin and gap width are adapted to distribute the resin in the channel grid by a capillary effect
Data Source
AI summary
An optical filter assembly comprises a plurality of optical filters and a filter frame holding the plurality of optical filters in a predefined pattern. A method for manufacturing such an optical filter assembly comprises providing diced optical filters, each optical filter having a specific spectral sensitivity. A mold is provided having an open top mold cavity and one or more filling ports which are in fluid communication with the mold cavity. The optical filters are picked and placed in the predetermined pattern in the mold cavity with a gap having a predetermined gap width between the optical filters. A channel grid is formed by the gaps between the optical filters. The channel grid is filled by feeding a liquid resin having a light blocking property to the one or more filling ports, wherein said resin and said gap width are adapted to distribute the resin in the channel grid by a capillary effect. The resin is allowed to cure so as to form the filter frame.