Passive Lens Adhered to Sensor Encapsulant for Optical Alignment
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Solution Overview
Problem
Manufacturing tolerances often result in misalignment of the optical axis of a lens with the central axis of a sensing area in sensor designs, reducing sensor sensitivity and efficiency.
Innovation Solution
A passive optical component with a pre-formed lens is adhered to an encapsulant covering the sensor, using an adhesive gel and a supporting structure with a protruding portion to minimize voids and ensure alignment, and fiducial marks for precise placement, allowing the optical axis to be substantially aligned with the center of the sensing area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a lens is integrated directly with the sensor during manufacturing, then the optical axis can be aligned with the sensing area center, but manufacturing tolerances cause misalignment that reduces sensor sensitivity
Solution Approach 1:
The optical system is segmented into separate components: a passive optical component (lens) and an active sensor component. The lens is formed as a separate passive optical component that can be independently manufactured and then attached to the sensor, allowing each component to be optimized and aligned separately to achieve better overall alignment precision.
Solution Approach 2:
The passive optical component is prepared in advance with a pre-formed lens structure before attachment to the sensor. This preliminary formation of the lens with its own optical axis allows for precise alignment to be established before final assembly, compensating for manufacturing tolerances that would otherwise cause misalignment.
2Manufacturing precision
If manufacturing tolerances are reduced to improve alignment, then optical performance improves, but manufacturing costs and process complexity increase
Solution Approach 1:
By segmenting the optical system into separately manufacturable components (passive optical component with lens and active sensor), the patent allows each component to be manufactured within standard tolerances, then assembled with precise alignment. This avoids the need for expensive high-precision manufacturing processes while achieving alignment tolerance below 20 μm through the alignment structure.
Solution Approach 2:
An encapsulant structure serves as an intermediary between the passive optical component and the active sensor, providing a platform for alignment. The encapsulant with its platform and recess portions enables precise positioning of the lens relative to the sensor without requiring the entire manufacturing process to operate at high precision, thus reducing overall manufacturing complexity and cost.
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 offset tolerances to below 20 μm, enhancing optical performance by minimizing voids and distortion, and maintaining alignment without increasing manufacturing costs or improving process tolerances.
Implementation Method 1
a passive optical component having a light guiding portion for guiding light beams
Data Source
AI summary
An optical device includes an active optical component including an optical area, an encapsulant covering the active optical component, and a passive optical component adhered to the encapsulant above the active optical component. The passive optical component has an optical axis, and the optical axis is substantially aligned with a center of the optical area.