Optical Sensor Shading Filters for Automated Alignment
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Solution Overview
Problem
Conventional optical sensors face increased manufacturing time due to the need for manual removal of block materials over alignment marks, which covers the sensing layer and disrupts alignment processes.
Innovation Solution
The use of a first and second shading filter, strategically positioned on the sensing layer to block specific components of light beams, replacing the need for block materials and allowing for automated alignment processes without manual removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If block material is formed on the sensing layer to block reflected light, then the quality of detection is improved, but the manufacturing time is greatly increased due to manual removal requirements
Solution Approach 1:
The block material is divided into multiple segments: a first block material layer covering the active area and a second block material layer covering the peripheral area with alignment marks. This segmentation allows selective removal of only the first block material layer while preserving the second layer that covers alignment marks, thereby eliminating manual removal operations and reducing manufacturing time without compromising detection quality.
Solution Approach 2:
The invention extracts and removes only the first block material layer from the sensing layer after alignment is completed, while leaving the second block material layer intact. This selective extraction eliminates the need for manual removal of block materials over alignment marks, significantly reducing manufacturing time while maintaining detection quality through the remaining block material structure.
2Object-affected harmful factors
If block material is disposed on the sensing layer to block reflected light, then reflected light noise is reduced, but alignment marks are covered making automated alignment impossible
Solution Approach 1:
The block material structure is segmented into two distinct layers: the first block material layer positioned over the active area to block reflected light, and the second block material layer positioned over the peripheral area containing alignment marks. This segmentation enables automated alignment by exposing alignment marks while maintaining reflected light blocking functionality through the first layer, thus resolving the contradiction between noise reduction and automation.
Solution Approach 2:
Different regions of the block material structure are assigned different functions: the first block material layer provides light blocking quality over the active area, while the second block material layer provides alignment mark exposure quality over the peripheral area. This local differentiation of quality allows both reflected light noise reduction and automated alignment to coexist without compromise.
3Ease of operation
If manual removal of block material is performed to enable alignment, then alignment marks become detectable, but manufacturing complexity and time increase significantly
Solution Approach 1:
The block material is segmented into removable first layer and permanent second layer, where only the first layer needs to be removed automatically after alignment. This segmentation simplifies the manufacturing process by eliminating manual intervention while ensuring alignment marks remain detectable through the exposed second layer, thereby reducing both operational complexity and manufacturing time.
Solution Approach 2:
The second block material layer is preliminarily formed to cover alignment marks before the alignment process. This preliminary action protects alignment marks during initial processing while allowing automated alignment systems to detect them, and subsequent automatic removal of only the first block material layer completes the process without manual intervention, reducing overall manufacturing complexity.
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 approach reduces manufacturing time by enabling automated alignment and image capture without manual intervention, improving the efficiency of optical sensor production.
Implementation Method 1
the second shading filter is configured to block a first component of the light beam, and the first shading filter is configured to block a second component of the light beam
Data Source
AI summary
An optical sensor includes a sensing layer, a first shading filter, a second shading filter, and an alignment mark. The sensing layer includes an active area, a shading area, and a peripheral area. The sensing layer includes sensing units located in the active area. The first shading filter is disposed on the shading area. The second shading filter is disposed on the first shading filter. The alignment mark is disposed on the peripheral area. When a light beam is emitted to the shading area, the second shading filter is configured to block a first component of the light beam, and the first shading filter is configured to block a second component of the light beam.