Multi-Layer Polymer Lens And Method Of Making Same

• US 20130188267A1
• Filed: 01/23/2012
• Published: 07/25/2013
• Est. Priority Date: 01/23/2012
• Status: Active Grant

• Current Assignee: Optiz, Inc.
• Original Assignee: Optiz, Inc.
• Inventors: Oganesian, Vage
• Granted Patent: US 8,570,669 B2
• Time in Patent Office: Days
• US Class Current: 359/718
• CPC Class Codes: B29D 11/00278 Lenticular sheets B29D11/00269 takes precedence
• CPC Class Codes: B29D 11/0073 Optical laminates
• CPC Class Codes: G02B 13/0085 employing wafer level optics
• CPC Class Codes: G02B 3/0012 characterised by the manufacturing method
• CPC Class Codes: G02B 7/025 using glue
• CPC Class Codes: H01L 2224/04042 Bonding areas specifically adapted for wire connectors, e.g. wirebond pads
• CPC Class Codes: H01L 2224/48091 Arched
• CPC Class Codes: H01L 2224/48464 the other connecting portion not on the bonding area also being a ball bond, i.e. ball-to-ball
• CPC Class Codes: H01L 24/05 of an individual bonding area
• CPC Class Codes: H01L 27/14618 Containers
• CPC Class Codes: H01L 2924/00 Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H01L 2924/00014 the subject-matter covered by the group, the symbol of which is combined with the symbol of this group, being disclosed without further technical details
• CPC Class Codes: H01L 2924/12042 LASER

Abstract

A multi-layered lens having a substrate with opposing first and second surfaces. The substrate is formed of a plurality of discreet polymer layers. A cavity is formed into the first surface and is defined by a non-planar cavity surface that acts as a lens surface. The cavity extends into and exposes each of the plurality of polymer layers. The compositions of the polymer layers can vary to provide optimized focal properties. Alignment marks in the form of cavities or protrusions can be formed at the first surface or the second surface, so that multiple lenses can be stacked together in an aligned manner to form a stacked lens assembly.

Claims

1. A lens, comprising:

a substrate having opposing first and second surfaces, wherein the substrate is formed of a plurality of discreet polymer layers; and

a cavity formed into the first surface and including a non-planar cavity surface in the substrate, wherein the cavity extends into each of the plurality of polymer layers.

2. The lens of claim 1, wherein a composition of one of the plurality of polymer layers varies from that of another of the plurality of polymer layers.

3. The lens of claim 1, wherein each of the plurality of polymer layers defines at least one portion of the non-planar cavity surface.

4. The lens of claim 1, further comprising:

a plurality of alignment marks formed at one of the first and second surfaces.

5. The lens of claim 4, wherein each of the plurality of alignment marks comprises a protrusion extending from the one first and second surface.

6. The lens of claim 4, wherein each of the plurality of alignment marks comprises a cavity formed into the one first and second surface.

7. A method of forming a lens, comprising:

forming a first polymer layer;

forming a first cavity into a top surface of the first polymer layer;

forming a second polymer layer on the top surface of the first polymer layer; and

forming a second cavity into a top surface of the second polymer layer that extends through the second polymer layer to the first cavity;

wherein the first and second cavities together include a non-planar cavity surface.

8. The method of claim 7, wherein a composition of the first polymer layer varies from that of the second polymer layer.

9. The method of claim 7, wherein each of the first and second polymer layers defines at least one portion of the non-planar cavity surface.

10. The method of claim 7, further comprising;

filling the first cavity with a material before the forming of the second polymer layer.

11. The method of claim 7, further comprising:

forming a plurality of alignment marks at the top surface of the second polymer layer or a bottom surface of the first polymer layer.

12. The lens of claim 11, wherein each of the plurality of alignment marks comprises at least one of a protrusion and a cavity.

13. The method of claim 7, further comprising:

forming a third polymer layer on the top surface of the second polymer layer; and

forming a third cavity into a top surface of the third polymer layer that extends through the third polymer layer to the second cavity;

wherein the first, second and third cavities together define the non-planar cavity surface.

14. The method of claim 13, wherein a composition of one of the first, second and third polymer layers varies from that of another of the first, second and third polymer layers.

15. The method of claim 13, wherein each of the first, second and third polymer layers defines at least one portion of the non-planar cavity surface.

16. The method of claim 13, further comprising;

filling the first cavity with a first material before the forming of the second polymer layer; and

filling the second cavity with a second material before the forming of the third polymer layer.

17. The method of claim 13, further comprising:

forming a plurality of alignment marks at the top surface of the third polymer layer or a bottom surface of the first polymer layer.

18. The lens of claim 17, wherein each of the plurality of alignment marks comprises at least one of a protrusion and a cavity.

19. A method of forming a lens, comprising:

forming a first polymer layer;

forming a first cavity into a top surface of the first polymer layer;

altering a shape of a sidewall of the first cavity;

forming a second polymer layer on the top surface of the first polymer layer;

forming a second cavity into a top surface of the second polymer layer; and

altering a shape of a sidewall of the second cavity;

wherein the second cavity includes a first non-planar cavity surface.

20. The method of claim 19, wherein a composition of the first polymer layer varies from that of the second polymer layer.

21. The method of claim 19, further comprising:

forming a plurality of alignment marks at the top surface of the second polymer layer or a bottom surface of the first polymer layer.

22. The lens of claim 21, wherein each of the plurality of alignment marks comprises at least one of a protrusion and a cavity.

23. The method of claim 19, further comprising:

forming a third polymer layer on the top surface of the second polymer layer;

forming a third cavity into a top surface of the third polymer layer; and

altering a shape of a sidewall of the third cavity;

wherein the third cavity includes a second non-planar cavity surface.

24. The method of claim 23, wherein a composition of one of the first, second and third polymer layers varies from that of another of the first, second and third polymer layers.

25. The method of claim 23, further comprising:

forming a plurality of alignment marks at the top surface of the third polymer layer or a bottom surface of the first polymer layer.

26. The lens of claim 25, wherein each of the plurality of alignment marks comprises at least one of a protrusion and a cavity.

27. A lens assembly, comprising:

a plurality of lenses each comprising;

a substrate having opposing first and second surfaces and an outer edge, wherein the substrate is formed of a plurality of discreet polymer layers, and

a cavity formed into the first surface and including a non-planar cavity surface in the substrate, wherein the cavity extends into each of the plurality of polymer layers;

wherein the plurality of lenses are stacked together such that adjacent ones of the plurality of lenses are affixed to each other by a bonding material; and

a layer of material that extends around and between the outer edges of the substrates.

28. The lens assembly of claim 27, wherein:

the outer edges of the substrates are round; and

the layer of material is cylindrical in shape.

29. The lens assembly of claim 27, wherein the layer of material is non-transparent.

30. The lens assembly of claim 27, wherein the non-planar cavity surface of one of the plurality of lenses has a shape that is different from that of the non-planar cavity surface of another of the plurality of lenses.

31. The lens assembly of claim 27, wherein for each of the plurality lenses, a composition of one of the plurality of polymer layers varies from that of another of the plurality of polymer layers.

32. The lens assembly of claim 27, wherein for each of the plurality lenses, each of the plurality of polymer layers defines at least one portion of the non-planar cavity surface.