Optical Sensor Light Shielding Layer Air Vent Design

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Solution Overview

Problem

Existing optical sensors face image quality degradation due to air bubbles trapped between the adhesive layer and the light shielding layer, which affect the optical refractive index during thermal processes.

Innovation Solution

A polymer material layer is filled into the openings of the light shielding layer, with its top surface protruding above the light shielding layer, creating air vents that allow air to escape, preventing bubble trapping and ensuring a tight attachment of the surface component.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a surface component is attached to the light shielding layer through an adhesive layer, then the surface component is fixed in position, but air bubbles are trapped in corners of the opening causing adhesive swelling and image quality degradation

Engineering Contradiction:

Improveattachment reliabilityVSAvoidair bubble trapping

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The opening in the light shielding layer is segmented into multiple sub-openings by forming protrusions that extend into the opening. This segmentation creates multiple smaller air escape paths, allowing air bubbles to be gradually expelled during the attachment process rather than being trapped in a single large cavity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The solution transitions from a two-dimensional flat opening to a three-dimensional structured opening with protrusions extending into the depth of the opening. This dimensional change creates channels and pathways that guide air bubble escape, transforming the attachment process from one that traps air to one that systematically expels it.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Strength

If the adhesive layer is applied to attach the surface component, then bonding is achieved, but the adhesive swells during thermal process affecting optical refractive index

Engineering Contradiction:

Improvebonding strengthVSAvoidoptical refractive index precision

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The protrusions are formed in the light shielding layer before the adhesive layer is applied. This preliminary structural modification creates air escape pathways that will be active during the subsequent adhesive application and thermal processing, preventing air trapping and adhesive swelling before they can occur.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The protrusions act as an intermediary structure between the light shielding layer and the adhesive layer. They provide a mechanical and optical interface that facilitates air bubble escape and prevents direct contact between trapped air and the adhesive, thereby preventing swelling while maintaining bonding strength.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If air bubbles are trapped between adhesive layer and light shielding layer, then attachment is incomplete, but subsequent thermal process causes adhesive swelling that degrades image quality

Engineering Contradiction:

Improveattachment process simplicityVSAvoidadhesive swelling

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The light shielding layer is modified to have a porous or channelled structure with protrusions that create void spaces and escape pathways. This porous-like structure allows air to be expelled during attachment, preventing the harmful effects of trapped air bubbles while maintaining the structural integrity of the light shielding layer.

Inventive Principle:

Principle #31Porous materials

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 solution enhances the image quality of optical sensors by preventing adhesive swelling and maintaining the optical refractive index, ensuring a bubble-free attachment process.

Implementation Method 1

a plurality of channels (i.e. air vents) are formed between the protruding portions of the polymer material layer. Therefore, when the surface component is attached to the light shielding layer by the adhesive layer, the air can be exhausted through the air channels

Methodology Applied

Scientific EffectAir venting:

Implementation Method 2

an adhesive layer disposed on the light shielding layer and the polymer material layer, and a surface component disposed on the adhesive layer

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS10770496B2Optical sensors and methods for forming the same

Publication Date: 2020.09.08 VISERA TECH CO LTD

AI summary

An optical sensor includes an optical layer disposed on a substrate, and a light shielding layer disposed on the optical layer, wherein the light shielding layer includes a first opening that partially exposes the optical layer. The optical sensor also includes a polymer material layer that fills the first opening, wherein a top surface of the polymer material layer is higher than a top surface of the light shielding layer. The optical sensor further includes an adhesive layer disposed on the light shielding layer and the polymer material layer, and a surface component disposed on the adhesive layer.