Optical IC Glass Stack With Thermally Conductive Fingers
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Solution Overview
Problem
Existing methods for producing refractive lenses and optically transparent windows are limited in creating high-definition optics with asymmetric or freeform surfaces, leading to spherical aberrations and high manufacturing complexity, especially with glass materials.
Innovation Solution
Utilizing additive manufacturing (AM) processes to deposit glass nanoparticles, allowing for the creation of optical components with integrated optical functions, such as antireflective coatings and thermally controlled optics, by controlling the geometry and refractive index through multiple layers of glass materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional cutting, grinding, and polishing methods are used to produce optical components, then manufacturing simplicity is maintained, but manufacturing precision and ability to create asymmetric or freeform surfaces deteriorates
Solution Approach 1:
The patent changes the fundamental manufacturing parameter from subtractive (cutting, grinding, polishing) to additive (depositing glass nanoparticles layer by layer). This enables precise control of surface geometry and refractive index by controlling deposition parameters, allowing creation of asymmetric and freeform surfaces with high precision without requiring complex post-processing steps.
Solution Approach 2:
The patent uses composite glass nanoparticle materials that can be deposited in multiple layers with varying compositions. By controlling the size, shape, and composition of glass nanoparticles, the patent achieves precise control over optical properties and surface morphology, enabling high-definition optics with complex surfaces that would be difficult to achieve with traditional single-material processing.
2Manufacturing precision
If multiple layers of glass materials are deposited via additive manufacturing, then optical performance control is improved, but manufacturing time increases
Solution Approach 1:
The patent performs preliminary actions by pre-synthesizing glass nanoparticles with controlled size distributions and compositions before deposition. This allows the actual manufacturing process to proceed more efficiently, as the complex nanoparticle synthesis and characterization is done in advance, enabling faster layer-by-layer deposition with precise optical property control.
Solution Approach 2:
The patent changes the deposition parameter scale by working with nanoscale particles rather than bulk materials. This enables rapid deposition of thin, uniform layers with precise compositional control, reducing the number of processing steps needed compared to traditional methods while maintaining or improving optical performance 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
Enables the production of high-definition optical components with reduced risk of damage, improved handling, and enhanced thermal management, while providing real-time monitoring and control of optical performance.
Implementation Method 1
depositing nanoparticles of a first material via an additive manufacturing process to form a base layer
Implementation Method 2
depositing nanoparticles of a second material via an additive manufacturing process to form a plurality of active layers on the base layer
Implementation Method 3
The plurality of active layers may be configured to change a refractive index based upon an applied voltage
Implementation Method 4
a plurality of thermally conductive fingers extending vertically between the first and second opposing sides and through the optical body
Data Source
AI summary
An optical device includes a base layer, and active layers on the base layer and having optical IC devices. The optical device also includes a cover layer over the base layer and encapsulating the optical IC devices, the base layer and the cover layer each having a glass material.