Reflowable Optical Diffuser Elements for High-Temperature Integration
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Solution Overview
Problem
High-temperature manufacturing processes, such as those used in surface mount technologies, can adversely impact the mechanical stability and optical performance of optical diffusers, making it challenging to integrate them into devices like mobile phones and other electronics without damage.
Innovation Solution
The method involves using reflowable materials for optical diffusers, where a polymer substrate with openings is filled with an epoxy diffuser material, hardened, and then separated into elements that retain mechanical stability and optical properties even when subjected to high temperatures, such as 270° C., by employing a reflow process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional diffusers are used in high-temperature manufacturing processes, then integration into electronic devices is achieved, but mechanical stability and optical performance deteriorate
Solution Approach 1:
The patent changes the material parameters of the diffuser by using a thermally stable polymer composite material that can withstand high temperatures (e.g., 270°C) without degrading. This material parameter change enables the diffuser to maintain its mechanical stability and optical performance during high-temperature reflow processes while being integrated into electronic devices
Solution Approach 2:
The patent employs a composite material consisting of a thermally stable polymer matrix combined with diffusing particles or structures. This composite structure provides both the optical diffusing function and the thermal stability required to survive high-temperature manufacturing processes, resolving the contradiction between ease of integration and reliability
2Productivity
If high temperatures are applied during reflow process, then integration of sensor modules is achieved, but diffuser material decomposes or deforms
Solution Approach 1:
The patent modifies the thermal parameter of the diffuser material by selecting a polymer composite with a glass transition temperature and decomposition temperature significantly higher than the reflow process temperature. This parameter change allows the material to remain stable during high-temperature processing while enabling efficient integration into devices
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 allows for the easy integration of optical diffusers into electronic devices during elevated temperature manufacturing processes without compromising their stability or performance, facilitating direct incorporation into assembly lines.
Implementation Method 1
The optical diffuser material can be, for example, an epoxy material, and can be dispensed, for example, by jetting. In some cases, the optical diffuser material is operable to diffuse light in the visible range part of the electromagnetic spectrum.
Implementation Method 2
An optical diffuser material is dispensed into the openings, and the optical diffuser material is hardened to form a sheet composed of regions of the optical diffuser material surrounded laterally by the polymer material.
Data Source
AI summary
A method of making optical diffuser elements (20) includes providing a substrate (100) composed of a polymer material and having openings (102) therein. An optical diffuser material (110) is dispensed into the openings (102), and the optical diffuser material (110) is hardened to form a sheet (200) composed of regions of the optical diffuser material (110) surrounded laterally by the polymer material. The method includes separating the sheet (200) into multiple optical diffuser elements (30) that retain their mechanical stability and optical properties when subjected to a reflow process.