Packaged Spatial Light Modulator Aperture Design
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Solution Overview
Problem
The high cost of spatial light modulators is significantly influenced by the expensive multi-layer dichroic coatings used in light blocking/absorbing apertures, which are difficult to form and increase the size of the die, thereby raising production costs.
Innovation Solution
A packaged spatial light modulator with a light blocking/absorbing mask having an aperture that matches the size of the pixel array, allowing incident light to be focused on a plane away from the pixel array, reducing the need for large apertures and minimizing the size of the die, and using lower-cost materials for the aperture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a light blocking/absorbing aperture with multi-layer dichroic coatings is used to block non-active areas, then light blocking effectiveness is improved, but manufacturing cost increases significantly
Solution Approach 1:
The patent replaces expensive multi-layer dichroic coating apertures with a simpler light blocking aperture made from less expensive materials. The aperture structure is simplified to a single layer or fewer layers, sacrificing some optical performance for significant cost reduction while maintaining adequate light blocking functionality for the application.
Solution Approach 2:
The patent changes the optical parameters of the aperture by reducing the number of coating layers and using materials with different optical properties. This parameter change allows the aperture to maintain sufficient light blocking capability while dramatically reducing manufacturing complexity and cost.
2Object-affected harmful factors
If the aperture size is increased to block surrounding areas, then light blocking effectiveness is improved, but the die size increases
Solution Approach 1:
The patent applies light blocking functionality selectively only where needed - specifically at the boundaries of the active pixel array area. Rather than using a large aperture that blocks all surrounding areas, the light blocking structure is localized to the precise regions where non-active area light needs to be blocked, minimizing the overall aperture size and die area.
3Object-affected harmful factors
If the distance between the aperture and the die is increased, then light blocking effectiveness is improved, but the die size increases
Solution Approach 1:
The patent moves the light blocking aperture from being positioned at a distance from the die to being integrated directly onto the die surface or package lid in close proximity. This dimensional repositioning allows the aperture to maintain effective light blocking through proper optical design while minimizing the horizontal die size required.
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 reduces the overall cost of the spatial light modulator by minimizing the size of the aperture and die, while maintaining effective light blocking and absorption, and allows for a more compact and cost-effective display system design.
Implementation Method 1
a light blocking/absorbing mask having an aperture through which visible light can pass into the package
Data Source
AI summary
A spatial light modulator comprises an array of individually addressable pixels enclosed within a space formed by a package lid and a package substrate. An aperture through which incident visible light pass into the package is formed on the package lid. In display systems employing the spatial light modulator, the illumination system is focused on a plane away from the pixels of the spatial light modulator so as to reduce cost.