Sinusoidal Alignment Structures for Optical Component Positioning
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Solution Overview
Problem
Conventional wafer-scale imaging systems face challenges in precise integration due to optical element misalignments, which degrade imaging system quality, and current technologies only enable mechanical alignment rather than optical tolerance alignment.
Innovation Solution
The development of alignment structures with modulated contours on imaging system fixturing components, allowing for full kinematic alignment through engagement of sinusoidally modulated surfaces, enabling precise optical alignment without the need for additional alignment marks or vision systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional mechanical alignment methods are used, then assembly is simplified, but alignment precision deteriorates to only mechanical tolerances (several microns) rather than optical tolerances
Solution Approach 1:
The alignment structures are designed to enable self-alignment between the common base and fabrication master through direct mechanical engagement of the modulated contour features, eliminating the need for external alignment marks or vision systems. The sinusoidally modulated contours on both surfaces automatically guide precise alignment when brought into contact.
Solution Approach 2:
The patent replaces optical alignment methods (using alignment marks and vision systems) with a purely mechanical alignment system. The modulated contour structures provide mechanical guidance that achieves optical-level precision through physical engagement, substituting complex optical-mechanical systems with a streamlined mechanical solution.
2Manufacturing precision
If rotational misalignment occurs in the common base, then offsets of optical elements increase proportionally to distance from center, but this degrades imaging system quality
Solution Approach 1:
The alignment structures perform preliminary alignment of the fabrication master to the common base before the actual imaging system assembly process begins. By establishing precise alignment in advance through the engaged modulated contours, the system prevents rotational misalignment from occurring during subsequent assembly operations, thereby preventing the proportional offset errors that would affect optical elements farther from the center.
3Manufacturing precision
If alignment structures with modulated contours are implemented, then full kinematic alignment is achieved, but manufacturing complexity increases
Solution Approach 1:
The patent applies sinusoidal modulation to the contour parameters of the alignment structures. This mathematical transformation of the surface geometry creates the interlocking modulated features that enable precise alignment. The sinusoidal parameterization provides a systematic way to generate the complex three-dimensional alignment features from simple two-dimensional base contours, making the manufacturing process more controllable despite the increased geometric complexity.
Data Source
AI summary
A method of mutually aligning first and second imaging system fixturing components forms a first alignment structure on the first imaging system fixturing component, a second alignment structure on the second imaging system fixturing component, and engages the first and second alignment structures to align, with optical accuracy, the first and second imaging system fixturing components.