Stacked Wafer Lens for 3D Camera Image Quality
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Solution Overview
Problem
Conventional wafer-level optics technologies result in lenses of poor quality, which are not optimally suitable for use in 3D cameras due to insufficient image quality, primarily because they can only manufacture up to two-element lenses, lacking the dimensional stability and image quality required for effective 3D camera performance.
Innovation Solution
The solution involves forming multiple wafer level optics pieces and stacking them to create multi-element lenses, specifically 3-element or 4-element lenses, by using multiple sets of wafer-level optics assemblies with glass substrates and polymer layers, along with IR filters and spacers, to achieve improved image quality and dimensional stability suitable for 3D cameras.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional wafer level optics utilize polymers formed on glass wafers to manufacture lenses, then the manufacturing process is simple and cost-effective, but the image quality is poor and insufficient for 3D camera applications
Solution Approach 1:
The patent divides the lens system into multiple separate wafer-level optical elements (typically 3-5 elements) that are manufactured individually using conventional wafer-level optics processes, then stacked and bonded together. Each element can be optimized for specific optical functions, and the segmentation allows achieving higher overall image quality while maintaining the manufacturing advantages of wafer-level processes.
Solution Approach 2:
The patent employs composite optical systems by combining multiple different optical elements (polymer lenses, glass substrates, IR filters, aperture layers) into a stacked assembly. This composite approach allows each material to contribute its strengths - polymers for molding flexibility, glass for substrate stability, and specialized filters for spectral control - achieving superior image quality suitable for 3D cameras.
2Device complexity
If conventional wafer level optics manufacture only up to two-element lenses, then the manufacturing complexity is low, but the dimensional stability and image quality are insufficient for 3D cameras
Solution Approach 1:
By segmenting the optical system into multiple discrete wafer-level elements that are stacked, the patent achieves higher dimensional stability. Each wafer maintains its own mechanical stability, and the stacked configuration provides better control over element spacing and alignment, which is critical for 3D camera performance.
Solution Approach 2:
The patent introduces intermediary bonding layers and spacer structures between the individual optical elements. These intermediaries provide precise mechanical coupling and spacing control, ensuring stable relative positioning of lens elements while allowing the overall system to maintain low complexity through standardized wafer-level manufacturing processes.
3Ease of manufacture
If conventional wafer level optics use polymers on glass wafers, then the production cost is low, but the lenses are not optimally suitable for 3D cameras due to poor image quality
Solution Approach 1:
The patent segments the optical system into multiple affordable wafer-level elements that can be manufactured using cost-effective polymer molding and glass substrate processes. By stacking these individually manufactured elements, the system achieves reliable optical performance for 3D cameras without requiring expensive single-element lens solutions.
Solution Approach 2:
The patent creates a composite optical system combining polymer lenses, glass substrates, and specialized filters. This composite approach leverages the cost advantages of polymer molding while incorporating glass and filter elements that enhance optical performance, achieving a balance between production cost and reliability suitable for 3D camera applications.
Data Source
AI summary
A multi-element lens includes a first assembly having first and second optical elements supported respectively on a top and a bottom of a first glass substrate. A second assembly has third and fourth optical elements supported on a top and bottom of a second glass substrate. The first and second assemblies are bonded together and diced to form multiple multi-element lenses.