Optical Lens Array Fabrication via Polymer Deformation
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Solution Overview
Problem
Current methods for manufacturing optical lens arrays result in systems with large dimensions and critical positional inaccuracies, and the control of complex contour shapes is not precise enough, leading to high costs for tooling and inaccuracies in peripheral structures.
Innovation Solution
A replication process involving a first mold with recesses, application of a polymer liquid, and a contact shaping substrate to deform and cure the liquid, followed by a second polymer layer to achieve accurate contour control, using flow stop patterns and specific mold designs to control resin flow and improve vertex control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional replication processes are used to manufacture optical lens arrays, then manufacturing speed and cost are improved, but manufacturing precision and contour shape control deteriorate
Solution Approach 1:
The method applies preliminary shaping actions to the polymer liquid before final curing. A first contact shaping substrate deforms the polymer liquid to achieve a first contour configuration, and a second contact shaping substrate further deforms it to achieve a second contour configuration. This preliminary shaping ensures precise contour control is built into the structure before the replication process completes.
Solution Approach 2:
The method changes the physical state and shape parameters of the polymer liquid through controlled deformation. By applying mechanical deformation through contact shaping substrates, the polymer liquid transitions from an initial state to configured states with specific contour shapes, enabling precise control of optical element geometry while maintaining replication efficiency.
2Ease of manufacture
If conventional replication processes are used, then manufacturing cost is reduced, but manufacturing precision and vertex control worsen
Solution Approach 1:
The method performs preliminary deformation of the polymer liquid using contact shaping substrates before final curing and replication. This preliminary action ensures vertex positions and contour shapes are pre-established, allowing precise vertex control to be achieved through the replication process without requiring expensive post-processing or complex tooling.
Solution Approach 2:
The method uses contact shaping substrates as templates that copy their surface geometry onto the polymer liquid. By designing these substrates with precise vertex positions and contour configurations, the replication process accurately copies these features to the final optical elements, achieving high precision through simple replication of pre-configured shapes.
3Device complexity
If simple replication processes are used, then device complexity is reduced, but manufacturing precision and positional accuracy worsen
Solution Approach 1:
The method incorporates preliminary positioning and shaping actions within the replication process itself. Contact shaping substrates are positioned against the polymer liquid before curing, establishing precise positional relationships and contour configurations. This preliminary positioning ensures high positional accuracy is achieved through the replication process without requiring complex alignment systems or post-processing steps.
Solution Approach 2:
The contact shaping substrates act as intermediary elements between the replication tool and the final optical elements. These substrates mediate the transfer of precise geometric information to the polymer liquid, enabling high positional accuracy and contour control to be achieved through a relatively simple replication process by using the substrates as precision intermediaries.
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
The method enables the fabrication of optical lens arrays with precise contour shapes and improved vertex control, reducing variations and achieving well-defined optical elements with accurate positioning and reduced manufacturing costs.
Implementation Method 1
curing said first polymer liquid to form an array of optical lens elements
Data Source
AI summary
The present invention relates to a method of fabricating an array of optical lens elements, comprising:providing a first mold having a plurality of recesses;applying a first polymer liquid in said plurality of recesses;providing a first contact shaping substrate;contacting said first contact shaping substrate with said first polymer liquid in said plurality of recesses, wherein said contact between said first contact shaping substrate and said first polymer liquid results in a deformation of the contour configuration of said first polymer liquid facing away from said plurality of recesses;curing said first polymer liquid to form an array of optical lens elements.