Optical: systems and elements – Single channel simultaneously to or from plural channels – By surface composed of lenticular elements
Reexamination Certificate
2000-02-29
2001-11-27
Epps, Georgia (Department: 2873)
Optical: systems and elements
Single channel simultaneously to or from plural channels
By surface composed of lenticular elements
C359S793000, C359S819000, C264S001100
Reexamination Certificate
active
06324010
ABSTRACT:
FIELD OF THE INVENTION
This invention relates to optical assemblies and methods for creating optical assemblies and lens systems that utilize lens arrays, and in particular, the methods for attaching and holding two or more lens arrays in precise position with respect to one another.
BACKGROUND OF THE INVENTION
Common industry practice for assembly of lens systems relies upon assembly of individual discrete lens elements with respect to one another for each individual lens system. This technique is useful for lens systems comprising a large lens elements, but is very difficult to use when lens elements are very small (less than 1 mm in diameter). Manufacturing many lens elements on a common carrier called a lens array streamlines the manufacture of the lens elements.
It is known to attach arrays of optical elements to electronic modules. Such assemblies have been described in U.S. Pat. No. 5,638,469, entitled “Microelectronic module having optical and electrical interconnects”, and U.S. Pat. No. 5,661,831, entitled “Optical module having self-aligned optical element and optical wave-guide by means of bumps on rectangular pads and method of assembling thereof”. However, the methods described in these patents are not optimal for creating single (i.e., individual) lens systems at a later time. Furthermore, many of the methods used to attach lens elements to electronic modules rely upon solder balls for alignment. Use of solder balls requires extra steps of patterning, solder deposition, and solder re-flow.
SUMMARY OF THE INVENTION
The object of the present invention is to enable accurate assembly of very small lens elements into lens systems, while these lens elements form parts of lens arrays.
According to one aspect of the present invention, a method of making a lens assembly with a plurality of lens arrays having a plurality of lenslets and at least one spacer having a plurality of holes, includes the steps of (i) arranging at least two lens arrays and the spacer, such that the spacer is located between the two lens arrays and the lenslets of one of the two lens arrays overlay the lenslets of another one of the two lens arrays and, the holes of the spaces are located between the corresponding lenslets of the two lens arrays; (ii) fixedly attaching the lens arrays and the spacer to one another to form an array assembly; and (iii) dividing the array assembly to create a plurality of individual lens systems.
According to another aspect of the present invention, the optical assembly includes at least two lens arrays and at least one spacer with a plurality of holes. The spacer is located between the two lens arrays and is fixedly attached to the two lens arrays. The spacer has a thickness of 0.05 to 0.5 mm. The lens arrays have a plurality of lenslets of no more than 1 mm in diameter. It is preferred that the lens arrays have a largest dimension of at least 5 mm.
It is an advantage of the present invention that in manufacturing lens assemblies using one, or more than one lens array, the size of the parts are increased in order to make them more manufacturable and more easily assembled.
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“Micro-jet Printing of Refractive Micro-lenses” by W. Royall Cox, Ting Chen, Chi Guan, Donald J. Hayes and Rick E. Hoenigman, Brian T. Teipan and Duncan L. MacFarlane, Proceedings, OSA Diffractive Optics and Micro-Optics Topical Meeting, Kailua-Kona, Hawaii, Jun. 1998.
Bowen John P.
Budinski Michael K.
Ludington Paul D.
McLaughlin Paul O.
Eastman Kodak Company
Epps Georgia
Greener William J.
Spector David N.
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