Recessed Mold Micro-lens Array for Imager Aberration Correction
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Solution Overview
Problem
Existing semiconductor-based imager and display technologies face challenges in maximizing light reception by micro-lenses due to complex subtractive manufacturing processes and optical aberrations, which affect the focal point and wavelength dependency of photo-conversion devices.
Innovation Solution
A method for manufacturing micro-lenses using a substrate with recessed areas as molds, filled with lens material to correct optical aberrations and adjust focal points, allowing for the formation of micro-lens arrays with varying profiles to optimize light focusing across different wavelengths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If known subtractive processes are used to form micro-lenses, then optical aberrations can be corrected, but the manufacturing process becomes complex and difficult
Solution Approach 1:
The patent inverts the conventional subtractive approach by using an additive process. Instead of removing material to form lens profiles, the invention forms recessed areas in the substrate and fills them with lens material. This inversion simplifies manufacturing while maintaining the ability to create varied lens profiles for optical aberration correction.
Solution Approach 2:
The substrate is prepared in advance by forming recessed areas with specific profiles before the lens material is added. This preliminary action allows the lens material to be deposited in a simplified manner while the pre-formed recesses ensure the final lens profiles are optimized for correcting optical aberrations.
2Illumination intensity
If micro-lenses are formed to focus light on photo-conversion devices, then light reception is maximized, but optical aberrations and wavelength dependency reduce efficiency
Solution Approach 1:
The patent applies local quality by creating micro-lenses with different profiles in different locations across the array. Each lens profile is specifically tailored to correct for local optical aberrations and wavelength dependency, allowing each region of the imager to be optimized for its specific detection requirements while maintaining high light reception.
Solution Approach 2:
The invention changes the physical parameters of the micro-lenses by varying their profiles according to the specific optical requirements of different regions. This parameter variation allows optimization of focal points for different wavelengths and correction of location-specific optical aberrations, thereby improving both light reception and focal accuracy.
3Device complexity
If a single micro-lens array is used, then device simplicity is maintained, but correction of optical aberrations and wavelength dependency is limited
Solution Approach 1:
The patent segments the micro-lens array into multiple distinct arrays, each with specifically designed profiles optimized for different optical functions. This segmentation allows each array to be tailored for correcting specific types of optical aberrations or handling different wavelength ranges, achieving superior optical performance while maintaining a relatively simple overall device structure.
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 simplifies the manufacturing of micro-lenses, enhances light reception by adjusting focal points for each color detected, and corrects optical aberrations, improving the efficiency of photo-conversion devices in imagers and displays.
Implementation Method 1
micro-lenses each associated with one of the pixel cells... collect external light and focus it on the photo-conversion device
Data Source
AI summary
A micro-lens and a method for forming the micro-lens is provided. A micro-lens includes a substrate and lens material located within the substrate, the substrate having a recessed area serving as a mold for the lens material. The recessed can be shaped such that the lens material corrects for optical aberrations. The micro-lens can be part of a micro-lens array. The recessed area can serve as a mold for lens material for the micro-lens array and can be shaped such that the micro-lens array includes arcuate, non-spherical, or non-symmetrical micro-lenses.