Optical Sensor Micro-Lens Array with Integrated Cover Plate
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Solution Overview
Problem
Current optical sensor devices, such as fingerprint identification devices, face inefficiencies due to the thickness and number of interfaces within their light collimators, which affect collimation performance and yield.
Innovation Solution
An optical sensor device design featuring a substrate with a light collimating structure that includes a transparent layer with micro-lenses and light-shielding layers, where a single transparent cover plate made of a single material is directly in contact with the micro-lenses, eliminating the need for an adhesive layer and reducing the overall thickness and number of interfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional light collimators with multiple internal structures are used, then collimation function is achieved, but device thickness increases and manufacturing yield decreases
Solution Approach 1:
The patent merges the light collimating function and light shielding function into a single integrated structure. The transparent layer with micro-lenses is directly formed on the substrate, eliminating the need for separate adhesive layers and intermediate structures. This integration reduces the number of interfaces and overall device thickness while maintaining collimation performance and improving manufacturing yield.
Solution Approach 2:
The patent extracts and eliminates unnecessary intermediate layers from the conventional structure. By removing adhesive layers and complex internal structures, the design achieves direct contact between the transparent cover plate and micro-lenses, reducing thickness and simplifying the manufacturing process.
2Reliability
If multiple interfaces and adhesive layers are used in light collimators, then structural stability is achieved, but collimation performance deteriorates and device complexity increases
Solution Approach 1:
The patent combines multiple functional layers into a single transparent layer structure that provides both mechanical support and optical collimation functions. The micro-lenses are directly formed on the substrate without requiring separate adhesive layers, reducing the number of interfaces from multiple to just one or two, thereby improving collimation performance and reducing device complexity.
3Ease of manufacture
If conventional multi-layer structures with adhesive layers are used, then assembly stability is achieved, but production cost increases and manufacturing precision requirements increase
Solution Approach 1:
The patent removes adhesive layers and intermediate structures from the conventional design. The transparent layer with micro-lenses is directly formed on the substrate using imprinting or molding techniques, eliminating the need for precise alignment and bonding processes. This reduces manufacturing precision requirements and lowers production costs while maintaining assembly stability.
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 design enhances collimation performance by reducing the thickness of the optical sensor device and eliminating unnecessary interfaces, leading to improved light focusing and increased yield while lowering production costs.
Implementation Method 1
imprinting the curable transparent material with the transparent template to form a plurality of convexes corresponding to the concaves
Implementation Method 2
curing the curable transparent material to form a transparent layer with an array of micro-lenses therein, wherein the curing of the curable transparent material includes adhering the transparent template to the curable transparent material
Implementation Method 3
The transparent layer has a plurality of micro-lenses arranged in an array
Implementation Method 4
The function of the light collimators is the collimating of light rays, to reduce energy loss due to light divergence
Data Source
AI summary
An optical sensor device and a method for forming the same are provided, including forming a curable transparent material on a substrate, wherein the substrate has a plurality of optical sensor units therein; providing a transparent template, which has a plurality of concaves; imprinting the curable transparent material with the transparent template to form a plurality of convexes corresponding to the plurality of concaves; and curing the curable transparent material to form a transparent layer having a micro-lens array. The step of curing the curable transparent material includes adhering the transparent template to the curable transparent material to act as a cover plate for the optical sensor device.