Wafer-Level Optics With Embedded Aperture Stop Structure
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Solution Overview
Problem
Wafer-level manufacturing of optical components faces challenges in integrating aperture stops without additional layers, leading to difficulties in handling and parallel processing, especially in miniaturized optoelectronic devices.
Innovation Solution
The substrate is structured to form an aperture stop within the lens component by creating a through-hole and embedding a lens element, allowing the substrate to define the aperture without separate elements, enhancing compactness and integration in optoelectronic devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If aperture stops are integrated without additional layers, then device complexity is reduced, but handling and parallel processing become difficult
Solution Approach 1:
The substrate is divided into multiple independent regions, each containing a through-hole with a lens element. This segmentation allows individual through-holes to be processed separately while maintaining overall integration, resolving the contradiction between reduced complexity and ease of handling.
Solution Approach 2:
The aperture stop function is achieved by creating through-holes that extend through the substrate thickness (third dimension), rather than using additional layers in the planar direction. This dimensional approach integrates the aperture function without adding processing complexity.
2Device complexity
If through-hole with lens element is created, then aperture stop function is integrated, but manufacturing precision requirements increase
Solution Approach 1:
The aperture stop function and lens element are merged into a single integrated structure within the substrate. The lens element is formed directly in the through-hole, combining two functions (aperture control and light focusing) into one manufacturing step, thereby reducing the cumulative precision requirements that would arise from separately aligning distinct components.
Solution Approach 2:
The substrate structure serves multiple functions simultaneously: it provides mechanical support, defines the aperture stop through the through-hole geometry, and houses the lens element. This multi-functionality eliminates the need for separate precision alignment between aperture and lens components.
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 stray light and scattering, enables light sealing, and facilitates channel separation in optical systems, resulting in a more compact and cost-effective design suitable for miniaturized devices.
Implementation Method 1
the substrate is structured to define an aperture stop of the optical component in correspondence of the through-hole to, during an operation of the optical component, partially block light and partially allow light to pass through the aperture stop
Data Source
AI summary
An optical component (200) including: a substrate (202) comprising a through-hole (206) extending from a first opening in a first surface (208a) of the substrate (202) to a second opening in a second surface (208b) of the substrate (202); and a lens element (204) at least partially embedded in the through-hole (206), wherein the substrate (202) is structured to define an aperture stop (212) of the optical component (200) in correspondence of the through-hole (206) to, during an operation of the optical component (200), partially block light and partially allow light to pass through the aperture stop (212), wherein the aperture stop (212) has a lateral dimension in a direction perpendicular to an optical axis of the optical component (200) less than a lateral dimension of a lens portion of the lens element (204) in the direction perpendicular to the optical axis of the optical component (200).