Thermal Deformation of Substrates for Inclined Optical Windows
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Solution Overview
Problem
Current methods for producing optical components with inclined or shifted optical windows face challenges in achieving high surface quality and flexibility, often resulting in unsatisfactory surface roughness and limited production flexibility due to material limitations and complex processing steps.
Innovation Solution
A method involving the use of reinforcement elements and substrates with precise arrangement and thermal deformation to create optical components with inclined or shifted optical windows, ensuring high surface quality and flexibility by using polished substrate sides and controlled deformation processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional etching or forming processes are used to create inclined optical windows, then the optical components can be manufactured, but the surface quality deteriorates with unsatisfactory surface roughness
Solution Approach 1:
The method applies preliminary action by placing reinforcement elements on the substrate before the forming process. These elements prevent unwanted deformation and maintain surface quality during the forming operation, thereby resolving the contradiction between manufacturability and surface roughness.
Solution Approach 2:
Reinforcement elements act as intermediaries between the forming tool and the substrate. They mediate the forming process by providing localized support and control, enabling the creation of inclined optical windows while preserving the underlying surface quality and minimizing roughness.
2Reliability
If complex processing steps are used to achieve inclined optical windows, then the optical properties can be improved, but the production flexibility deteriorates due to material limitations
Solution Approach 1:
The method changes parameters by using reinforcement elements with varying geometries, materials, and positions to achieve different inclination angles and optical properties. This allows flexible adaptation to various optical requirements without being constrained by material limitations, resolving the contradiction between reliability and adaptability.
3Manufacturing precision
If additional processing steps are used to achieve high surface quality, then the optical properties improve, but the production time increases
Solution Approach 1:
The reinforcement elements are placed before the forming process, performing the surface protection function in advance. This eliminates the need for additional post-processing steps to restore surface quality, thereby maintaining high surface quality while reducing production time and improving productivity.
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
The method achieves optical components with high surface quality, low surface roughness, and flexibility in design, reducing the need for additional processing steps and enabling cost-effective production of optical components with precise optical properties.
Implementation Method 1
heating and deforming the first substrate such that at least part of the area of the first substrate covered by the respective reinforcement element shifts and/or tilts
Data Source
Figure 1a~1b
Figure 2a~2c
Figure 2d~2e
AI summary
The method according to the invention is used for producing optical components, in particular covers for encapsulating micro-systems, wherein at least one reinforcing element, which is produced before being arranged, is arranged on a first substrate, as a result of which a stack is produced. This stack is heated after being connected to a second substrate, as a result of which the first substrate is deformed such that at least one region, covered by the reinforcing element, of the first substrate is moved and/or is inclined or the first substrate is brought into contact with the reinforcing element. In an alternative method according to the invention, the reinforcing element is arranged on the second substrate, wherein this stack is then connected to the first substrate. The first substrate is subsequently heated and deformed such that a region of the first substrate is brought into contact with the reinforcing element.