Optical Spacer Aperture Control via Thermal Glue Molding
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Solution Overview
Problem
Conventional lens apertures are limited in location and structure due to binary pseudo random and chromium processes, restricting the size, shape, and configuration of lens apertures in lens arrays.
Innovation Solution
A method involving the use of thermal glue, where a mold is generated to create an optical spacer with a controlled aperture, allowing for independent control of aperture height, width, and distance by dispensing and curing the glue within the mold, followed by stacking it onto a lens plate to form a lens assembly with customizable optical characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If binary pseudo random and chromium processes are used to manufacture lens apertures, then the manufacturing process is established and repeatable, but the aperture location and structure are limited and cannot be customized
Solution Approach 1:
The patent changes the manufacturing approach from conventional binary pseudo random and chromium processes to a thermal glue-based molding process. This parameter change enables customizable aperture locations and structures by varying the mold configuration and thermal glue dispensing patterns, while maintaining manufacturing repeatability through controlled curing processes.
Solution Approach 2:
The patent introduces thermal glue as an intermediary material between the mold and the lens aperture structure. The thermal glue serves multiple functions: it fills the mold cavity to create the aperture structure, it provides thermal conduction for curing, and it enables flexible shape control without the limitations of conventional chromium etching processes.
2Manufacturing precision
If conventional manufacturing processes are used, then the process is simple and established, but the aperture height, width, and distance cannot be independently controlled
Solution Approach 1:
The patent segments the aperture manufacturing process into independent controllable parameters by using a mold-based thermal glue dispensing system. The mold design allows independent control of aperture height, width, and distance from the lens surface, enabling precise dimensional control while maintaining manufacturing simplicity through a single-step curing process.
Solution Approach 2:
The patent adds dimensional control capability by transitioning from two-dimensional chromium pattern deposition to three-dimensional thermal glue molding. This enables independent control of aperture height, width, and depth parameters that were not independently controllable in conventional processes.
3Reliability
If lens aperture size and shape are constrained by lens dimensions, then the manufacturing process is straightforward, but the optical characteristics such as MTF cannot be optimized
Solution Approach 1:
The patent applies local quality control by enabling different aperture configurations (size, shape, location) to be optimized for specific optical requirements. The thermal glue molding process allows customization of aperture characteristics at each lens position to optimize local optical performance metrics such as Modulation Transfer Function (MTF) while maintaining overall manufacturing consistency.
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
Enables the creation of optical spacers with customizable apertures, allowing for precise control of optical characteristics such as MTF (Modulation Transfer Function), overcoming the limitations of prior art manufacturing processes.
Implementation Method 1
The thermal glue may be cured prior to releasing the mold from the optical spacer.
Data Source
AI summary
A method of manufacturing an optical spacer includes dispensing thermal glue within a mold; pressing the thermal glue using an optical spacer substrate to generate an optical spacer including an aperture; and, releasing the mold from the optical spacer. The thermal glue may be cured prior to releasing the mold from the optical spacer.