Truncated Lens Manufacturing via Segmented Replication and Precision Dicing
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Solution Overview
Problem
Current methods for manufacturing passive optical components, such as lenses, with unique shapes for applications in multi-channel optical devices face challenges in achieving precise, close proximity and efficient mass production, particularly in creating optical structures with truncated apertures and ensuring optical separation between channels.
Innovation Solution
The method involves wafer-level manufacturing of precursor optical structures followed by material removal techniques like dicing, laser cutting, or micro-machining to produce specially shaped passive optical components with truncated apertures, allowing for precise control of optical axis proximity and separation, using embossing with flow control and replication processes to achieve high-quality, miniaturized optical modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional replication methods are used to manufacture optical components, then mass production is achieved, but manufacturing precision and unique shapes (truncated apertures) cannot be realized
Solution Approach 1:
The manufacturing process is segmented into two distinct stages: first, replication of complete spherical lenses using high-speed molding for mass production; second, selective truncation of lens apertures using precision cutting tools. This segmentation allows each stage to optimize for its specific requirement - volume production and precision shaping respectively - thereby resolving the contradiction between mass production efficiency and manufacturing precision for unique shapes.
Solution Approach 2:
The complete spherical lens structure is formed in advance through replication molding before the truncation step. This preliminary formation of the full lens ensures that the base optical component is ready for subsequent precision modification without requiring complex tooling for the final shape, thus maintaining both high productivity in the formation stage and precision in the truncation stage.
2Volume of moving object
If optical components are manufactured with close proximity for multi-channel devices, then device miniaturization is achieved, but optical separation and reduced cross-talk become difficult
Solution Approach 1:
The invention introduces asymmetric truncation of lens apertures, where lenses for different channels are cut to different extents or patterns. This asymmetric modification creates distinct optical pathways for each channel even when lenses are in close proximity, enabling optical separation without increasing the overall module size, thus resolving the contradiction between miniaturization and cross-talk reduction.
Solution Approach 2:
The truncation process applies local quality modification to specific regions of each lens aperture. By selectively removing material from specific portions of each lens while leaving other portions intact, the invention creates channel-specific optical characteristics that maintain separation between adjacent channels while preserving the compact overall structure of the multi-channel device.
3Manufacturing precision
If traditional manufacturing methods are used, then simple processes are maintained, but unique optical structures and close axis alignment cannot be achieved
Solution Approach 1:
The manufacturing process is segmented into two distinct stages: first, replication of complete spherical lenses using high-speed molding for mass production; second, selective truncation of lens apertures using precision cutting tools. This segmentation allows each stage to optimize for its specific requirement - volume production and precision shaping respectively - thereby resolving the contradiction between mass production efficiency and manufacturing precision for unique shapes.
Solution Approach 2:
The invention replaces complex mechanical alignment and custom machining processes with a simplified two-step system: standard replication molding followed by automated precision truncation. This substitution of traditional complex mechanical manufacturing with a more systematic approach reduces overall process complexity while achieving superior optical axis alignment precision through the controlled truncation geometry.
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 enables the efficient production of optical structures with unique shapes and close optical axis alignment, enhancing the performance of multi-channel devices by reducing cross-talk and improving optical separation, while maintaining high throughput and quality in mass production.
Implementation Method 1
hardening the replication material through UV irradiation or heating
Implementation Method 2
hardening the replication material through UV irradiation or heating
Data Source
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AI summary
The invention relates to wafer-level manufacturing of optical devices such as modules comprising micro-lenses. In one aspect, passive optical components such as truncated lenses are manufactured by providing a substrate on which a multitude of precursor optical structures is present; and removing material from each of said multitude of precursor optical structures. Another aspect comprises a method for manufacturing a device comprising a set of at least two passive optical components, said method comprising the steps of using a tool obtained by carrying out the steps of manufacturing a precursor tool having a replication surface; and modifying said replication surface by removing material from said precursor tool. An yet another aspect comprises a method for manufacturing a device comprising a set of at least two passive optical components, wherein the method comprises the step of using a master comprising a replication surface comprising, for each of said passive optical components, a first portion describing a shape corresponding to the shape of at least a portion of the respective passive optical component, wherein the master comprises, in addition, at least one protruding portion protruding from at least one of said first portions of said replication surfaces.