Polymer Miniature Lens Manufacturing via Patterned Wettable Substrate
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Solution Overview
Problem
Traditional methods for manufacturing micro-lenses, such as high-temperature glass molding and ink-jetting, face challenges in achieving precise alignment, reliability, and transparency, particularly for larger collimator applications in optoelectronic transceivers, due to high material and manufacturing costs, and limitations in substrate and material choices.
Innovation Solution
A method involving a substrate with lens forming patterns that confine liquid polymer, where the periphery area defines the polymer lens perimeter and the interior area ensures substrate contact, allowing for precise control of lens position and dimension, improved reliability, and enhanced transparency, using photoresist rings or other patterns to optimize the polymer lens formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional high-temperature glass molding or etching methods are used to manufacture micro-lenses, then the lenses can endure high temperature assembly processes, but the material cost and manufacturing cost are considerably high
Solution Approach 1:
The invention changes the material parameter from traditional glass to polymer material, which allows the lenses to be manufactured at lower costs while still meeting the requirements for high-temperature assembly processes through proper polymer selection and curing methods
Solution Approach 2:
The invention uses polymer materials that are more cost-effective than traditional glass materials, reducing both material cost and manufacturing cost while maintaining the necessary performance characteristics for OE component applications
2Measurement precision
If ink-jetting technology is used to manufacture micro-lenses by direct dispensing, then the position of micro-lens is with high precision, but the dimension and shape of the micro-lens are determined by dispensing volume and surface tension which limits control accuracy
Solution Approach 1:
The invention applies a patterned wettable layer on the substrate before dispensing the liquid polymer. This preliminary action creates predefined confinement regions that guide the liquid polymer to specific locations and shapes, enabling precise control over both position and dimensions of the resulting micro-lenses
Solution Approach 2:
The patterned wettable layer serves as an intermediary between the dispensing process and the final lens formation. It mediates the interaction by providing specific wettability patterns that control where the liquid polymer spreads and how it forms, enabling precise dimensional and shape control
3Ease of manufacture
If a wettable layer is deposited on the substrate to form micro-lenses, then the lens formation process is simplified, but the micro-lens does not contact with the substrate directly resulting in poor reliability and transparency
Solution Approach 1:
The invention creates a patterned wettable layer with spatially varying properties - the wettable regions provide controlled adhesion for lens formation while non-wettable regions prevent unwanted spreading. This local quality variation enables the liquid polymer to contact the substrate directly at specific locations, improving both reliability and transparency while maintaining process simplicity
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 enables the precise manufacturing of polymer miniature lenses with improved reliability and transparency, reducing spherical aberration and maintaining optical alignment, thus addressing the limitations of existing methods while being cost-effective and applicable to larger collimator sizes.
Implementation Method 1
curing the liquid polymer after the liquid polymer reaches equilibrium shape and is confined to the periphery area
Implementation Method 2
the dimension and shape of the micro-lens is in turn determined by the dispensing volume and its surface tension to reach equilibrium profile on the substrate
Data Source
AI summary
A method for manufacturing a polymer miniature lens on a substrate with the lens forming pattern, and the liquid polymer is dispensed therein. The lens forming pattern having a periphery area and an interior area, most portion of the periphery area having a property of confining liquid polymer, while the interior area having at least one portion exposing the surface of the substrate; depositing liquid polymer onto the lens forming pattern; and curing the liquid polymer after the liquid polymer reaches equilibrium shape and is confined to the periphery area. The invention also discloses a collimator including the polymer miniature lens.