We propose a novel manufacturing technology for monolithic polymer optics such as aspherical lenses. UV-replication is well known from wafer level optics. Here supporting glass wafers remain in the final lens. This severely limits the degrees of freedom of the optical design. In addition, material shrinkage, when the polymer is cured, limits reasonable sag heights of the lenses, so that only low-resolution imaging optics are possible. In our UV-replication approach, there is no glass substrate in the individual lenses and the shrinkage is compensated in the process to achieve minimum form error. This enables large sag heights and aspherical lens profiles on both sides of thin menisci as required in high-resolution imaging optics which so far can be realized by injection molding only. Combining this with a high degree of parallelization such as in wafer-level-optics is the key to a large-scale and economical production. We present details of our new technology at the example of realized demo systems for 3D-sensing applications using nano-optical structures, imaging use-cases in endoscopy and those ultimately targeting mobile phone camera modules.
UV-replication is well known from wafer level optics, where supporting glass wafers remain in the final lens severely limiting the degrees of freedom of the optical design. In addition, material shrinkage occurring during the curing of the polymer limits reasonable sag heights of the lenses, so that only low-resolution imaging optics are possible. In our UVreplication process, the glass substrate in the individual lenses can now be omitted and a compensation of the shrinkage is achieved with minimum form error. As a result, monolithic components with double-sided aspherical lens profiles of large sag height can be manufactured, as required in high-resolution imaging optics, which previously could only be realized by injection molding. Unlike injection molding, the replication is carried out at room temperature saving large portions of energy required. In combination with a high degree of parallelization as in wafer-level-optics, which is the key to large-scale production, a more environmental-friendly production is possible, since the number of replication machines and thus the required clean room space are significantly reduced. As a further advantage, the used materials meet high temperature requirements and even withstand reflow-soldering performed at 260°C. We present details of our new technology at the example of realized demo systems for 3D-sensing applications using nano-optical structures and imaging use-cases aiming at high-volume, low-cost and high-performance solutions.
We propose a scalable and energy-saving technology for monolithic polymer components such as aspherical lenses. UVreplication is well known from wafer level optics, where supporting glass wafers remain in the final lens severely limiting the degrees of freedom of the optical design. In addition, material shrinkage when the curing the polymer limits reasonable sag heights of the lenses, so that only low-resolution imaging optics are possible. In our approach, the glass substrate in the individual lenses is omitted and a compensation of the shrinkage is achieved with minimum form error. This enables sag heights and aspherical lens profiles on both sides of thin menisci as required in high-resolution imaging optics so far realized by injection molding only. In contrast to injection molding, the replication is carried out at room temperature which saves energy and leads to a more eco-friendly production. In addition, low-cost materials for molds and lens masters can be used so that demonstrators, prototypes, small series and products in medium volumes of complex imaging systems can now be addressed economically for the first time. These smaller manufacturing volumes were so far limited to spherical glass lenses with their known drawbacks with respect to complexity and miniaturization compared to aspheres. In addition, the used materials are compliant to high temperature requirements even surviving reflow-soldering performed at 260°C. We present details of our new technology at the example of realized demo systems towards highvolume, low-cost and high-performance lens stacks ultimately targeting mobile imaging applications.
We have developed a new UV-replication technology for monolithic aspherical polymer lenses. Proprietary process control allows to manufacture lenses with form errors and tolerances suitable for imaging applications, similar to those originating from optical injection molding. However, since UV-replication is carried out at room temperature, in contrast to injection molding, there is a large choice for material selection for the molds and consequently the lens masters can be manufactured much cheaper. With these low initial fabrication costs demonstrators, prototypes, small series and even products in medium volumes of complex imaging systems can now be addressed economically for the first time. Those are otherwise typically limited to spherical glass lenses with all their drawbacks compared to aspheres. Polymer-on-glass UV-replication is well known from wafer level optics. But here the supporting glass wafers remain in the final lens, severely limiting the degrees of freedom of the optical design. In addition, material shrinkage occurring during hardening limits reasonable sag heights of the lenses, so that only low-resolution imaging optics are possible. In our case, the glass substrate in the individual lenses can now be omitted and a full compensation of the shrinkage is achieved with minimum form error. Sag heights of up to 1.8mm and aspherical lens profiles on both sides of thin menisci have already been realized with additional peripheral structures for mechanical self-alignment in materials that even survive reflow-soldering. In this paper we present the benefits of our new technology and the process chain, discuss applied materials and show some demo systems so far realized.
Single-use endoscopes show a steady growth in medical applications due to the advantage of omitted cross-patient infections. The devices benefit in terms of the imaging optics from the developments in wafer-level-optics (WLO) which was once considered to become the fabrication technique for all high volume applications. However, the restrictions in achievable vertex heights of the lenses, the necessity of the glass wafers within the optical path and the limited number of lenses per stack are still obstacles when targeting resolutions beyond HD.
We have developed a new and fully scalable fabrication method for monolithic aspherical polymer lenses similar to those originating from optical injection molding. In contrast to the later, high-temperature resistant UV-curing materials as in WLO are used, which are even compliant to reflow-soldering processes. In consequence, a new tool-set for low-cost, high-volume and high-resolution imaging optics becomes available. It overcomes the restrictions of WLO-based lens techniques and thus provides new degrees of freedom in lens design and manufacturing. Furthermore, in contrast to WLO and injection molding, low initial fabrication costs enable cost-effective demonstrators, prototypes, and small series products. Thanks to the scalability of the processes, also high-volume applications can be addressed cost-efficiently. In this paper we present the benefits of our new technology and show some endoscopy camera module demo systems we realized with our optics so far.
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