UV Laser Curing of Epoxy for Optical Component Alignment
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Solution Overview
Problem
Legacy epoxy curing processes using traditional UV lamps or LEDs are slow and non-customizable, leading to component misalignment and increased optical losses due to adhesive shrinkage during the curing process, which is exacerbated by the need for a subsequent thermal cure.
Innovation Solution
The use of UV lasers to cure photosensitive and UV-initiated cationic epoxy resins, allowing for precise control over the cure location and behavior, enabling faster and more customizable curing with reduced material shifting and improved thermal stability by minimizing the time spent in the low-viscosity state.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional UV lamps or LED lamps are used to cure epoxy, then the curing process can be performed, but the curing time is long (15 seconds to 60 seconds or longer) and component misalignment occurs due to adhesive shrinkage
Solution Approach 1:
The patent divides the curing process into two distinct stages: an initial rapid UV cure that sets component positions and prevents shrinkage-induced misalignment, followed by a subsequent thermal cure that completes the epoxy curing. This segmentation allows the UV cure to occur quickly (reducing time loss) while maintaining manufacturing precision by freezing components in place before final curing.
Solution Approach 2:
The patent employs periodic action by applying UV light in a controlled manner during the initial curing stage to achieve rapid setting of the epoxy adhesive. This periodic UV exposure creates an initial cured layer that prevents component shifting, followed by a different curing phase (thermal), thereby achieving both speed and precision through timed, alternating curing actions.
2Manufacturing precision
If traditional UV lamps or LED lamps are used to cure epoxy, then the curing process can be performed, but component shifting occurs during the curing process due to non-uniform shrinkage
Solution Approach 1:
The patent segments the curing process into an initial UV cure stage that rapidly sets component positions and prevents shrinkage-induced misalignment, followed by a subsequent thermal cure stage that completes the epoxy curing. This segmentation maintains component position stability during the critical initial phase while managing overall process complexity through a structured two-stage approach.
Solution Approach 2:
The patent applies preliminary action by performing an initial UV cure of the epoxy before the thermal cure. This preliminary UV curing creates a partially cured state that stabilizes component positions and prevents shifting during the subsequent thermal processing, thereby ensuring manufacturing precision is maintained throughout the complete curing process.
3Reliability
If a subsequent thermal cure is required after UV curing, then complete epoxy curing is achieved, but the total process time increases to one or more hours
Solution Approach 1:
The patent segments the curing process into two distinct stages: an initial rapid UV cure that achieves partial curing and sets component positions within seconds, followed by a subsequent thermal cure that completes the epoxy curing. This segmentation allows the time-consuming thermal cure to occur after positions are fixed, reducing the impact of total process time on manufacturing precision while ensuring complete curing for reliability.
Solution Approach 2:
The patent applies preliminary action by performing an initial UV cure of the epoxy before the thermal cure. This preliminary curing step creates a partially cured state that maintains component positions during the subsequent thermal processing, thereby ensuring both complete cure reliability and reduced overall process time by preventing misalignment during the lengthy thermal phase.
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 significantly reduces component shifting during the curing process, enhances manufacturing tolerances, and allows for the integration of materials with specific properties, such as low shrinkage and high thermal conductivity, resulting in improved thermal performance and reduced optical losses.
Implementation Method 1
A UV laser beam may then pass through the transparent substrate and interact with an initiator in the epoxy resin to cause the epoxy to cure.
Implementation Method 2
The UV laser beam may then pass through the transparent substrate and interact with an initiator in the epoxy resin
Data Source
AI summary
Embodiments herein relate to curing of an epoxy using an ultraviolet (UV) laser. A volume of epoxy may be coupled to an area of a surface, and the volume of epoxy is cured and surrounded by material other than cured epoxy, where the area of the surface is substantially equal to a diameter of the UV laser beam used to cure the epoxy. Other embodiments may be described and/or claimed.