Rectangular Prism Light Guide Cladding via Segmented Wafer Processing
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Solution Overview
Problem
Current methods for manufacturing light guides face inefficiencies in transporting light with minimal loss, particularly in optoelectronic modules, where existing technologies do not effectively utilize materials with high refractive indices like sapphire to optimize light transmission and cladding for ambient and infrared light.
Innovation Solution
A method involving the injection and curing of polymers or metal layers as claddings around rectangular prism-shaped bars, followed by dicing to create singulated light guides, allowing for efficient fabrication of light guides with specific optical properties and refractive indices, enabling effective light transmission in optoelectronic modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple light guides are manufactured individually using traditional methods, then manufacturing precision and quality control are maintained, but productivity is low and manufacturing time is excessive
Solution Approach 1:
The patent applies segmentation by dividing the manufacturing process into modular stages: multiple rectangular bars are arranged in a wafer-like configuration on a support substrate, allowing simultaneous processing of multiple light guides. The bars are separated by spacing elements that enable independent cladding application and subsequent dicing into individual light guides, achieving parallel manufacturing while maintaining quality control.
Solution Approach 2:
The patent merges multiple manufacturing operations into a single integrated process. Multiple light guides are manufactured simultaneously by applying cladding material across all bars in the array, then dicing through all bars at once to create individual light guides. This combines what would traditionally be sequential operations into parallel processing, dramatically improving productivity.
2Reliability
If cladding material is applied thickly to ensure complete coverage, then protection and light transmission optimization are improved, but material usage increases and manufacturing cost rises
Solution Approach 1:
The patent applies local quality by using spacing elements positioned between adjacent bars to control cladding material distribution. The spacing elements create defined gaps that limit polymer flow to only where needed, ensuring complete coverage of each bar's surface while preventing excessive material accumulation in inter-bar regions. This localized control optimizes both coverage quality and material efficiency.
3Productivity
If bars are closely spaced to maximize wafer utilization, then manufacturing efficiency is improved, but complete cladding coverage becomes difficult to achieve
Solution Approach 1:
The patent introduces spacing elements as intermediary components between adjacent bars. These elements serve multiple functions: they maintain precise spacing to allow cladding material to flow around bar ends for complete coverage, provide separation for independent processing, and can be removed later. This intermediary structure enables close spacing for high productivity while preserving manufacturing precision through controlled material flow paths.
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 facilitates the production of light guides with optimized claddings that enhance light transmission and reduce losses, enabling the manufacture of high-quality light guides for optoelectronic modules, such as those using sapphire or other high refractive index materials, which can handle ambient and infrared light efficiently.
Implementation Method 1
The first polymer is injected so as to cover four sides of each of multiple rectangular prism-shaped bars... A second polymer is injected so as to cover the first polymer on the four sides of the bars
Implementation Method 2
The light is transmitted through the light guide by total internal reflection
Data Source
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AI summary
The present disclosure describes light guides and a method of manufacturing light guides that include a rectangular prism-shaped bar, a first polymer or metal cladding on four sides of the rectangular prism-shaped bar, and a second polymer cladding disposed on the first polymer cladding on the four sides of the rectangular prism-shaped bar.