Abstract
The present method relates to a method for printing a three-dimensional lens structure, comprising a step of depositing multiple fragments of printing material on a substrate and a step of curing the deposited fragments to build up said three-dimensional lens structure, wherein said substrate comprises a mould having a well defined surface area.
Claims
1. A method for printing a three-dimensional lens structure, comprising a step of depositing multiple fragments of printing material on a substrate and a step of curing the deposited fragments to build up said three-dimensional lens structure, wherein said substrate comprises a mould having a well defined surface area for obtaining said three-dimensional lens structure.
2. A method according to claim 1, further comprising forming an intermediate layer in said mould before said step of depositing multiple fragments of printing material on said mould.
3. A method for printing a three-dimensional lens structure according to claim 1, further comprising removing said mold from said three-dimensional lens structure after curing.
4. A method according to claim 1, further comprising bonding together two three-dimensional lens structures obtained according to the present method, wherein the contact surface between these two three-dimensional lens structures is formed by the surface remote from the mould having a well defined surface area.
5. A method according to claim 4, wherein the lens structures of the two three-dimensional lens structures differ from each other.
6. A method according to claim 4, wherein said step of bonding comprises the application of a bonding medium chosen from the group of adhesive and printing material used for printing said three-dimensional lens structures.
7. A method according to claim 4, wherein one or more layers are interposed between said two three-dimensional lens structures, wherein said one or more layers are chosen from the group of structured coatings, light blocking, filters, black matrix, PEDOT and LCD films, foils, diaphragm, aperture, additional glass substrates and flex prints.
8. A method according to claim 1, wherein said step of depositing multiple fragments of printing material comprises the deposition of at least two zones of multiple fragments of printing material, wherein said at least two zones comprise different types of printing material.
9. A method according to claim 8, wherein said step of depositing of said at least two zones of multiple fragments of printing material takes place simultaneously.
10. A method according to claim 8, wherein said step of depositing of said at least two zones of multiple fragments of printing material takes place after one another.
11. A method according to claim 8, wherein at least one zone comprises a light blocking material.
12. A method according to claim 1, wherein the lens structure(s) thus obtained is/are interlocked with peripheral structures.
13. A method according to claim 1, wherein said mould is a wafer having well defined surface areas.
14. A method according to claim 1, wherein said three dimensional lens structure is of the diffractive or refractive type.
15. A method according to claim 1, wherein said step of depositing multiple fragments of printing material on said substrate is carried out such that no inclusion of air bubbles in the thus deposited multiple fragments of printing material takes place.
Description
[0043] FIG. 1 shows in A the first step of the present method for printing a three-dimensional lens structure, i.e. the provision of a mould 1 having a well defined surface area 2. In step B multiple fragments of printing material 3 are deposited on the mould and cured to build up a three-dimensional lens structure 4 as shown in step C. The three-dimensional lens structure 4 shown here comprises a convex shape and, on the side opposite to the convex shape, a flattened side.
[0044] FIG. 2 shows in A the first step of the present method for printing a three-dimensional lens structure, i.e. the provision of a mould 1 having a well defined surface area 2. In step B an intermediary layer 6 of for example liquid UV curable or thermo setting polymer is applied to ensure a perfect match with the subsequent deposited fragments of the printing process. In step C multiple fragments of printing material 3 are deposited on intermediary layer 6 present in mould 1 and cured to build up a three-dimensional lens structure 5 as shown in step C. In step D three-dimensional lens structure 5 is shown, build up of cured resin material 3 wherein the concave part of three-dimensional lens structure 5 is provided with intermediary layer 6.
[0045] FIG. 3 shows a construction wherein two three-dimensional lens structure 5 are bonded together by means of a bonding medium 7 wherein an optical light path with at least two precise lens surfaces is obtained. Although three-dimensional lens structure 5 shows the presence of an intermediary layer 6, such a layer is optional. In the area between three-dimensional lens structure 5 one or more additional layers may be present, such as structured coatings, light blocking, filters, films, foils, diaphragm, aperture, additional glass substrates and flex prints. In more detail, the bonding medium layer 7 can be functionalized by the provision of one or more functional layers, such as structured (e.g. holes) coatings, light blocking, filters, black matrix, PEDOT & LCD films, foils, diaphragm, aperture, additional glass substrates, flex prints, for example FR4. Although FIG. 3 shows the bonding of two three-dimensional lens structure 5 having both a concave lens structure, other combinations of lens shapes are also possible, for example convex shape lens structures.
[0046] FIG. 4 shows in A a construction wherein the step of depositing multiple fragments of printing material comprises the deposition of at least two zones of multiple fragments of printing material. Mould 10 is provided with a well defined surface area 15 of the concave shape. Zone 11 and zone 12 are two zones comprising different types of printing material. In a preferred embodiment zone 11 consist of a light blocking material, whereas zone 12 consist of a transparent material, both materials have been deposited of fragments to build up said three-dimensional zones 11, 12. In B mould 10 is provided with a well defined surface area 16 of the convex shape. Zone 13 and zone 14 are two zones comprising different types of printing material. In a preferred embodiment zone 13 consist of a light blocking material, whereas zone 14 consist of a transparent material, both materials have been deposited of fragments to build up said three-dimensional zones 13, 14. In C the both three-dimensional zones 13, 14 and three-dimensional zones 11, 12 are bonded together by the use of a bonding agent 17. Materials in zones 11, 12, 13 and 14 may have different optical properties. Moulds 10, 20 can be removed after bonding three-dimensional zones 13, 14 and three-dimensional zones 11, 12. The composite construction consisting of three-dimensional lens structure 12, 14 surrounded by material 11, 13 can be used in an optical module. Layers 11, 13 can be used as a spacer. In the area between three-dimensional lens structure 12, 14 one or more additional layers may be present, such as structured coatings, light blocking, filters, films, foils, diaphragm, aperture, additional glass substrates and flex prints.
[0047] FIG. 5 shows in A the result of the present method for printing a three-dimensional lens structure, i.e. a mould 30 having a well defined surface area 31 of the concave shape provided with a segment of deposited multiple fragments of printing material as a three-dimensional lens structure 32. In FIG. 5B is shown a mould 40 having a well defined surface area 41 of the convex shape provided with a segment of deposited multiple fragments of printing material as a three-dimensional lens structure 42. In FIG. 5C both moulds 30, 40 and its three-dimensional lens structure 32, 42 are bonded together by the use of a bonding agent 35. The area located between the moulds 30, 40 can be filled with an additional curable resin 36 thereby obtaining a lens structure 32, 42 embedded in resin material 36. Such a cured resin material can have a light blocking function. Materials of zones 32, 35, 42 and may have different optical properties. Moulds 30, 40 can be removed after bonding together three-dimensional lens structure 32, 42 and filling the area located between moulds 30, 40. The composite construction consisting of three-dimensional lens structure 32, 42 surrounded by resin 36 can be used in an optical module. Resin material 36 can be used as a spacer. In the area between three-dimensional lens structure 32, 42 one or more additional layers may be present, such as structured coatings, light blocking, filters, films, foils, diaphragm, aperture, additional glass substrates and flex prints.
[0048] FIG. 6 shows a construction 60 manufactured according to the present method wherein a first segment 61 consists of fragments of printing material. First segment 61 has a sloped area 63 functioning as a reflective surface for light beam 65. Construction 60 further consists of a second segment 62 manufactured according to the present method, wherein the type of material for second segment 62 is different from the type of material for first segment 61. FIG. 6 is an embodiment of the deposition of at least two zones of multiple fragments of printing material, wherein the at least two zones comprise different types of printing material.
[0049] FIG. 7A shows an embodiment of a three-dimensional lens structure manufactured according to the present method. In mould 70 having a well defined surface area 73 multiple fragments of printing material 71 have been deposited and cured. The area 72 above the deposited and cured fragments has been provided with other multiple fragments of printing material 71 to build up the three-dimensional lens structure. FIG. 7A also shows dicing lines 74, 75 for singulating optical element 76, as shown in FIG. 7B.
[0050] FIG. 8A shows an optical element 80 consisting of a lens structure 81 and a baffle 82, both manufactured according to the present method wherein multiple fragments of different types of printing material have been deposited on a mould (not shown) and cured.
[0051] FIG. 8B shows an array with optical element 83 with an interlocked layer 84. Layer 84 may be printed according to the present method. Layer may also be an inserted patterned substrate. In the latter case the method of depositing multiple fragments of printing material is interrupted allowing the inserting the patterned substrate 84. A function of layer 84 is for example light blocking, filtering or electrical, thermal conductive. Layer 84 may also be structured in a pattern, e.g. a conductive circuit or a flex foil circuit.
[0052] FIG. 9 shows an optical element 90, wherein multiple fragments printing material 91 have been deposited on a Fresnel lens mould. However, the complete mould is not shown here. The multiple fragments printing material may be different for each lens. In addition each lens shape may be different as well. A diaphragm 92 is present around each lens and has been preferably manufactured according to the present method. The diaphragm may be circular, apodized. The segments between lenses 91 is made of a light blocking material, preferably manufactured according to the present method. In a preferred embodiment a frame or aperture hole substrate, for example FR4, may be inserted, for example when specific stiffness of the optical element is needed. Additional layers of deposited multiple fragments printing material may be applied on top of optical element 90.
[0053] FIG. 10A shows an optical element obtained by depositing multiple fragments of printing material 101, 103 on a mould 100 having a well defined surface area 104. The method further comprises the deposition of multiple fragments of printing material for forming 102, i.e. a light blocking element. The three zones of multiple fragments of printing material 101, 102, 103 may be printed at the same time, i.e. parallel, or one after the other.
[0054] FIG. 10B shows an optical element obtained by depositing multiple fragments of printing material and consisting of zones 102, 106, 105. The three zones of multiple fragments of printing material 102, 106, 105 may be printed at the same time, i.e. parallel, or one after the other.
[0055] FIG. 100 shows a top view of the optical element from FIG. 10B consisting of zones 102, 106, 105.
[0056] FIG. 11 shows a specific type of mould 110. Mould 110 comprises recesses 112 and a well defined surface area 113. After depositing multiple fragments of printing material on the mould 110 and curing the deposited fragments stand off elements 112 embedded in material 111 are obtained. Stand off elements 112 preferably have a light blocking function.
