Optical Microstructure Plate Alignment Marks and Mold Spoiler Design
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Solution Overview
Problem
Conventional methods for fabricating multiple optical elements face challenges in accurate alignment and material distribution, leading to issues like air bubbles and excess glue during the formation of micro-lens arrays, which affect the performance of optical components.
Innovation Solution
The introduction of optical microstructure plates with period alignment marks for mold alignment and universal alignment marks for bonding, along with a mold design featuring a concave and buffer zones with spoilers to manage excess material and prevent air bubbles, ensures precise alignment and efficient material distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If alignment marks are added to the substrate, then alignment precision is improved, but device complexity increases
Solution Approach 1:
The patent implements two types of alignment marks on the substrate: period alignment marks for precise positioning during mold fabrication and universal alignment marks for general bonding operations. This multi-functional marking system allows a single substrate design to serve multiple alignment purposes, improving both fabrication precision and bonding accuracy without requiring separate alignment systems for each operation.
2Reliability
If epoxy glue amount is increased to ensure sufficient filling, then manufacturing reliability is improved, but harmful factors increase due to overflow and air bubbles
Solution Approach 1:
The mold cavity is segmented into a main bonding area and a buffer zone by introducing a spoiler structure. The spoiler divides the cavity space, creating a designated buffer region that captures excess epoxy glue and air bubbles, preventing them from contaminating the main bonding area and ensuring reliable micro-lens formation.
Solution Approach 2:
The patent converts the harmful effects of excess epoxy glue and air bubbles into beneficial outcomes by directing them into the buffer zone. The spoiler structure guides the overflow glue and trapped air bubbles away from the bonding interface, transforming potential defects into a self-cleaning mechanism that protects the quality of the micro-lens array.
3Manufacturing precision
If a buffer zone with spoiler is added to the mold, then manufacturing precision is improved by preventing defects, but device complexity increases
Solution Approach 1:
The mold cavity is segmented into a main bonding area and a buffer zone by introducing a spoiler structure. The spoiler divides the cavity space, creating a designated buffer region that captures excess epoxy glue and air bubbles, preventing them from contaminating the main bonding area and ensuring reliable micro-lens formation.
Data Source
AI summary
An optical microstructure plate and mold for fabricating the same is disclosed. The optical microstructure plate comprises a substrate. An optical microstructure element is formed on the substrate. A period alignment mark is disposed on the substrate to provide alignment for fabricating the optical microstructure element by a mold. A universal alignment mark is disposed on the substrate to provide alignment for bonding another plate therewith. Specifically, the mold comprises a concave within a mold substrate, a spoiler around the concave, and a buffer zone adjacent to the spoiler.