Optical Element Spacer Section for Adhesive Overflow Control

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Solution Overview

Problem

Conventional methods for manufacturing optical element wafers and modules face issues with adhesive variation, leading to unstable optical characteristics due to uneven adhesive thickness and overflow, which affects lens spacing and optical performance.

Innovation Solution

The introduction of a spacer section with a tapered portion on the optical element wafer, where the adhesive is positioned only in the space between the bottom portions of the spacer sections, preventing overflow and ensuring stable lens spacing by controlling the adhesive's placement and spreading.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If adhesive is applied between optical elements to bond them together, then the bonding strength is improved, but the adhesive thickness varies and overflows causing unstable optical characteristics

Engineering Contradiction:

Improvebonding strengthVSAvoidadhesive thickness uniformity

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent introduces a spacer section with a specific structure that creates a localized adhesive receiving space with controlled depth and width. This local structural modification ensures uniform adhesive thickness only in the bonding region, while other areas of the optical element maintain their original properties. The spacer section acts as a localized constraint that prevents adhesive overflow without affecting the overall optical performance.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The spacer section serves as an intermediary element between the optical element and the adhesive. It mediates the bonding process by providing a controlled interface that regulates adhesive flow and thickness. The tapered portion of the spacer section specifically manages the adhesive spreading, ensuring consistent bonding strength while preventing the harmful effect of variable adhesive thickness.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If adhesive is applied to bond optical elements, then the bonding strength is improved, but adhesive overflow occurs affecting lens spacing and optical performance

Engineering Contradiction:

Improvebonding strengthVSAvoidadhesive overflow

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The spacer section is designed with a tapered portion that preemptively counteracts the adhesive overflow tendency. By creating a gradual transition in the adhesive receiving space, the structure prevents adhesive from spreading beyond the intended bonding area before the bonding process completes. This preliminary structural constraint eliminates the harmful overflow effect while maintaining adequate bonding strength.

Inventive Principle:

Principle #9Preliminary anti-action

Solution Approach 2:

The spacer section creates a localized adhesive containment zone with specific geometric properties. The tapered portion provides a gradual transition that confines adhesive within the desired boundary, preventing overflow into adjacent optical regions. This local structural control ensures that bonding strength is maintained in the adhesive region while overflow is prevented at the boundaries.

Inventive Principle:

Principle #3Local quality

3Stability of the object's composition

If a spacer section with tapered portion is introduced to control adhesive placement, then lens spacing stability is improved, but the device structure becomes more complex

Engineering Contradiction:

Improvelens spacing stabilityVSAvoidstructure complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The spacer section is integrated directly into the optical element structure, merging the spacing function and adhesive control function into a single component. The tapered portion is formed as part of the optical element body, eliminating the need for separate adhesive control fixtures or additional structural elements. This merging approach maintains lens spacing stability while minimizing the increase in device complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The spacer section performs multiple functions simultaneously: it maintains the optical element spacing, controls adhesive placement, prevents adhesive overflow, and provides structural support. By combining these functions into a single integrated structure, the patent achieves lens spacing stability without proportionally increasing device complexity, as the same structural feature serves multiple purposes.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS8547470B2Optical element, optical element wafer, optical element wafer module, optical element module, method for manufacturing optical element module, electronic element wafer module, method for manufacturing electronic element module, electronic element module and electronic information device

Publication Date: 2013.10.01 SHARP KK

AI summary

An optical element according to the present invention includes: an optical surface at a center portion thereof; and a spacer section having a predetermined thickness on an outer circumference side of the optical surface, wherein a bottom portion for positioning an adhesive is provided on a further outer circumference side of the spacer section with a tapered portion interposed therebetween.