Printed Optical Elements Preventing Ink Coalescence
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Solution Overview
Problem
Existing methods for producing optical elements, such as lenses and fibers, using printing techniques face challenges in preventing coalescence between neighboring elements during the printing process, which limits the ability to create miniaturized, high-density optical and optoelectronic circuits suitable for mass production.
Innovation Solution
The use of a scanning printing technique that applies a transparent convex protuberance with an additional layer of ink, where the ink is deposited in a liquid state and controlled by surface tension to prevent merging, allowing for precise shaping and spacing of optical elements without coalescence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-density optical elements are printed using liquid ink techniques, then miniaturization and production volume are improved, but coalescence between neighboring elements occurs
Solution Approach 1:
A separating layer is deposited between neighboring optical elements before the liquid ink is applied. This preliminary action creates physical barriers that prevent coalescence during the printing process, enabling high-density miniaturized elements to be produced without merging while maintaining manufacturing precision
Solution Approach 2:
The separating layer acts as an intermediary substance between adjacent optical elements. This intermediate layer prevents direct contact and coalescence of the liquid ink from neighboring elements, allowing high-density printing while maintaining element separation and manufacturing precision
2Manufacturing precision
If tracing printing techniques are used to deposit material along defined paths, then manufacturing precision is improved, but production speed and cost effectiveness deteriorate
Solution Approach 1:
The patent replaces the mechanical tracing approach (robot following defined paths) with a scanning printing technique that deposits liquid ink in a different manner. This substitution enables faster production speeds while maintaining manufacturing precision through controlled liquid deposition patterns rather than mechanical tracing
3Ease of manufacture
If known printing techniques are used to produce optical elements, then ease of manufacture is improved, but coalescence prevention and element isolation deteriorate
Solution Approach 1:
The separating layer is deposited as a preliminary action before applying the liquid ink for optical elements. This simple preliminary step prevents coalescence and ensures element isolation while maintaining the ease of manufacture through a straightforward two-step process: deposit separating layer, then deposit optical element ink
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 method enables the production of miniaturized, high-density optical and optoelectronic circuits by preventing coalescence and allowing for precise control over the shape and spacing of optical elements, facilitating mass production and reducing costs.
Implementation Method 1
the ink being deposited in a liquid state, as opposed to manufacturing techniques involving the deposition of a solid substance which is then transformed, for example by heating, into a liquid deposit
Data Source
Figure 1~4
Figure 5a~5e
Figure 6a~6f
AI summary
The device comprises optical elements such as microlenses or optical fibers that are printed with liquid ink using known scanning printing techniques such as flexography. Each optical element (11, 12, 13, 14) has a transparent core (111, 121, 131, 141) printed with a first layer of ink, sufficiently far from the nearest cores so as not to fuse with them by coalescence, before being hardened. This core (111, 121, 131, 141) is then covered with one or more additional layers (112, 113, 122, 123, 132, 133, 142, 143), which may be solid areas, to finalize the shape of the optical element. The cross-section of the optical elements is determined by the difference in surface tension between said additional layers (112, 113, 122, 123, 132, 133, 142, 143) and the printing support (10).