U.S. patent application number 12/555880 was filed with the patent office on 2010-10-28 for imprinting mold and method for making lens array.
This patent application is currently assigned to HON HAI PRECISION INDUSTRY CO., LTD.. Invention is credited to TAI-CHERNG YU.
Application Number | 20100270692 12/555880 |
Document ID | / |
Family ID | 42991393 |
Filed Date | 2010-10-28 |
United States Patent
Application |
20100270692 |
Kind Code |
A1 |
YU; TAI-CHERNG |
October 28, 2010 |
IMPRINTING MOLD AND METHOD FOR MAKING LENS ARRAY
Abstract
An exemplary method for making a lens array is as follows. An
imprinting mold and a substrate are provided. A blob of molding
material is applied on each molding section of the substrate. The
first alignment marks, and the second alignment mark of the
imprinting mold are aligned with the fourth alignment marks, and
the third alignment mark of one of the imprinting regions,
respectively. The imprinting mold is pressed on the molding
material on the imprinting region. The pressed portions of the
imprinting region are solidified to obtain lenses in the imprinting
region. The imprinting mold is pressed on another one of the
imprinting region, and the imprinting mold is removed. This process
is repeated for each other imprinting region. Thus, a lens array is
obtained.
Inventors: |
YU; TAI-CHERNG; (Tu-Cheng,
TW) |
Correspondence
Address: |
Altis Law Group, Inc.;ATTN: Steven Reiss
288 SOUTH MAYO AVENUE
CITY OF INDUSTRY
CA
91789
US
|
Assignee: |
HON HAI PRECISION INDUSTRY CO.,
LTD.
Tu-Cheng
TW
|
Family ID: |
42991393 |
Appl. No.: |
12/555880 |
Filed: |
September 9, 2009 |
Current U.S.
Class: |
264/1.38 ;
264/2.7; 425/412 |
Current CPC
Class: |
B29C 33/303 20130101;
G02B 3/0056 20130101; B29C 33/30 20130101; B29D 11/00278 20130101;
B29C 33/00 20130101; B29C 2043/5833 20130101; B29C 2043/3488
20130101; G02B 3/0031 20130101; B29L 2011/0016 20130101; B29C 43/58
20130101; B29C 43/021 20130101 |
Class at
Publication: |
264/1.38 ;
425/412; 264/2.7 |
International
Class: |
B29D 11/00 20060101
B29D011/00; B28B 3/00 20060101 B28B003/00 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 27, 2009 |
CN |
200910301879.2 |
Claims
1. An imprinting mold comprising a molding surface, the molding
surface comprising: a plurality of microstructures defined thereat;
a plurality of first alignment marks adjacent each of the
microstructures; and a second alignment mark.
2. The imprinting mold of claim 1, wherein the second alignment
mark is formed at a periphery of the molding surface.
3. The imprinting mold of claim 1, wherein the first alignment
marks are protrusions protruding from the molding surface.
4. The imprinting mold of claim 1, wherein the first alignment
marks are recesses defined in the molding surface.
5. The imprinting mold of claim 1, wherein the second alignment
mark is a protrusion protruding from the molding surface.
6. The imprinting mold of claim 1, wherein the second alignment
mark is a recess defined in the molding surface.
7. The imprinting mold of claim 1, wherein the second alignment
mark has a larger size than that of each of the first alignment
marks.
8. The imprinting mold of claim 1, wherein two of the plurality of
first alignment marks are arranged symmetrically opposite each
other across the center of a corresponding one of the
microstructures, and are spaced apart from the microstructure.
9. A method for making a lens array, the method comprising: (1)
providing an imprinting mold, the imprinting mold comprising a
molding surface, the molding surface comprising a plurality of
microstructures defined thereat, a plurality of first alignment
marks adjacent each of the microstructures, and a second alignment
mark; (2) providing a substrate, the substrate comprising a
surface, the surface being divided into a plurality of imprinting
regions, a third alignment mark corresponding to the second
alignment mark being formed in each of the imprinting regions, each
of the imprinting regions being divided into a plurality of molding
sections, a plurality of fourth alignment marks being formed in
each of the molding sections, the fourth alignment marks
corresponding to the first alignment marks; (3) applying a blob of
molding material on each of the molding sections of at least one of
the imprinting regions; (4) aligning the first alignment marks and
the second alignment mark of the imprinting mold with the fourth
alignment marks and the third alignment mark of one imprinting
region which has the molding material applied thereon,
respectively; (5) pressing the imprinting mold on the molding
material on the imprinting region; (6) solidifying the pressed
portions of molding material on the imprinting region to obtain a
plurality of lenses on the imprinting region; and (7) repeating (3)
if and as needed and repeating (4) through (6) as needed to obtain
a lens array comprising a plurality of the lenses.
10. The method of claim 9, wherein the molding material is selected
from the group consisting of epoxy resin, acrylate-based resin,
polyurethane, and polymerized siloxane.
11. The method of claim 9, wherein the pressed portions are
solidified by ultraviolet (UV) light irradiation.
12. The method of claim 9, wherein the third alignment mark is a
protrusion protruding from the surface of the substrate.
13. The method of claim 9, wherein the third alignment mark is a
recess defined in the surface of the substrate.
14. The method of claim 9, wherein the fourth alignment marks are
protrusions protruding from the surface of the substrate.
15. The method of claim 9, wherein the fourth alignment marks are
recesses defined in the surface of the substrate.
16. A method for making a lens array, the method comprising: (1)
providing an imprinting mold, the imprinting mold comprising a
molding surface, the molding surface comprising a plurality of
microstructures defined thereat, a plurality of first alignment
marks adjacent each of the microstructures, and a second alignment
mark, the second alignment mark being formed at a periphery of the
molding surface; (2) providing a substrate, the substrate
comprising a surface, the surface being divided into a plurality of
imprinting regions, a third alignment mark corresponding to the
second alignment mark being formed in each of the imprinting
regions, each of the imprinting regions being divided into a
plurality of molding sections, a plurality of fourth alignment
marks being formed in each of the molding sections, the fourth
alignment marks corresponding to the first alignment marks; (3)
applying a blob of molding material on each of the molding sections
of at least one of the imprinting regions; (4) aligning the first
alignment marks and the second alignment mark of the imprinting
mold with the fourth alignment marks and the third alignment mark
of one imprinting region which has the molding material applied
thereon, respectively; (5) pressing the imprinting mold on the
molding material on the imprinting region; (6) solidifying the
pressed portions of molding material on the imprinting region to
obtain a plurality of lenses on the imprinting region; and (7)
selectively repeating any one or more of (3) through (6) if and as
required to obtain a lens array comprising a plurality of the
lenses.
Description
BACKGROUND
[0001] 1. Technical Field
[0002] The present disclosure relates to an imprinting mold that
includes alignment marks, and to a method for making a lens array
using such kind of imprinting mold.
[0003] 2. Description of Related Art
[0004] Imprinting technology is a simple process with low cost,
high throughput and high resolution. Imprinting technology is
widely used for making a lens array in a wafer lens package (WLP)
process.
[0005] In an imprinting process involving a large substrate, a
large size imprinting mold is usually employed to produce a lens
array on the substrate. However, the large size imprinting mold may
be very expensive to make due to the need for high precision.
Furthermore, it may be unduly time-consuming to manufacture the
large size imprinting mold.
[0006] Therefore, an imprinting mold and a method for making a lens
array which can overcome the above mentioned problems are
desired.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Many aspects of the present embodiments can be better
understood with reference to the following drawings. The components
in the drawings are not necessarily drawn to scale, the emphasis
instead being placed upon clearly illustrating the principles of
the present embodiments. Moreover, in the drawings, all the views
are schematic, and like reference numerals designate corresponding
parts throughout the several views.
[0008] FIG. 1 is an isometric view of an imprinting mold including
a plurality of first alignment marks and a plurality of second
alignment marks according to an exemplary embodiment of the present
invention.
[0009] FIG. 2 is a cross-sectional view of the imprinting mold of
FIG. 1, taken along line II-II thereof.
[0010] FIG. 3 is an isometric view of a substrate including a
plurality of third alignment marks and a plurality of fourth
alignment marks according to an exemplary embodiment of the present
invention.
[0011] FIG. 4 is a cross-sectional view of the substrate of FIG. 3,
taken along line IV-IV thereof.
[0012] FIG. 5 is similar to FIG. 4, but showing the substrate with
a blob of molding material applied to each of molding sections
thereof.
[0013] FIG. 6 shows the imprinting mold of FIG. 2 and the substrate
of FIG. 5, wherein the first alignment marks and the second
alignment marks of the imprinting mold are aligned with the fourth
alignment marks and the third alignment marks of one of imprinting
regions of the substrate, respectively.
[0014] FIG. 7 is similar to FIG. 6, but showing the imprinting mold
pressed on the molding material on the imprinting region, and the
pressed portions of the molding material being solidified with
ultraviolet (UV) light.
[0015] FIG. 8 is similar to FIG. 7, but showing the imprinting mold
pressed on molding material on another one of the imprinting
regions of the substrate, and the pressed portions of the molding
material being solidified with UV light.
[0016] FIG. 9 is similar to FIG. 8, but with the imprinting mold
having been removed, thus showing a lens array formed on the
substrate.
DETAILED DESCRIPTION
[0017] Various embodiments will now be described in detail below
with reference to the drawings.
[0018] Referring to FIG. 9, an exemplary method for making a lens
array 400 is described in detail as follows:
[0019] Referring to FIGS. 1 and 2, an imprinting mold 100 is
provided. The imprinting mold 100 includes a molding surface 110. A
plurality of microstructures 120 are defined in the molding surface
110. The microstructures 120 are configured for molding the lens
array 400. In the present embodiment, the microstructures 120 are
recesses defined in the molding surface 110. It can be understood
that in alternative embodiments, the microstructures 120 can be
protrusions protruding from the molding surface 110. In the present
embodiment, a surface of each microstructure 120 is aspheric. It
can be understood that in alternative embodiments, the surface of
each microstructure 120 can be spherical.
[0020] A plurality of first alignment marks 130 are formed on the
molding surface 110. In the present embodiment, the first alignment
marks 130 are protrusions protruding from the molding surface 110.
It can be understood that in alternative embodiments, the first
alignment marks 130 can be recesses defined in the molding surface
110. Two first alignment marks 130 are adjacent to each
microstructure 120. Each of the first alignment marks 130 can be,
for example, cross-shaped, T-shaped, I-shaped, F-shaped or
E-shaped. In the present embodiment, each of the first alignment
marks 130 is cross-shaped. In the present embodiment, two first
alignment marks 130 are arranged symmetrically opposite each other
across the center of the corresponding microstructure 120, and are
spaced apart from the microstructure 120. It can be understood that
the number and the arrangement of the first alignment marks 130 can
be varied according to the requirements of practical
applications.
[0021] Two second alignment marks 140 are formed at two opposite
peripheries of the molding surface 110. In the present embodiment,
the second alignment marks 140 are protrusions protruding from the
molding surface 110. In alternative embodiments, the second
alignment marks 140 can be recesses defined in the molding surface
110. Each of the second alignment marks 140 can be, for example,
cross-shaped, T-shaped, I-shaped, F-shaped or E-shaped. In the
present embodiment, each of the second alignment marks 140 is
cross-shaped. In the present embodiment, the two second alignment
marks 140 are arranged along an imaginary horizontal line, at two
opposite ends of the molding surface 110, respectively. It can be
understood that the number and the arrangement of the second
alignment marks 140 can be varied according to the requirements of
practical applications. In the present embodiment, each of the
second alignment marks 140 has a larger size than each of the first
alignment marks 130.
[0022] Referring to FIGS. 3 and 4, a substrate 200 is provided. The
substrate 200 includes a surface 210. The surface 210 is divided
into four imprinting regions 220 (demarcated by broken lines in
FIG. 3). It can be understood that the number of imprinting regions
220 is not limited to four. In alternative embodiments, the number
of imprinting regions 220 can be less than four or more than
four.
[0023] Two third alignment marks 230 are formed at two opposite
peripheries of each imprinting region 220. The third alignment
marks 230 of each imprinting region 220 are positioned
corresponding to the second alignment marks 140 of the imprinting
mold 100. In the present embodiment, the third alignment marks 230
are recesses defined in the surface 210. In the present embodiment,
the third alignment marks 230 have the same shape as the second
alignment marks 140; that is, the third alignment marks 230 are
cross-shaped. It can be understood that the number and the
arrangement of the third alignment marks 230 can be varied
according to the requirements of practical applications.
[0024] Each of the imprinting regions 220 is divided into a
plurality of molding sections 222 (one of which is demarcated by
broken lines in FIG. 3). Two fourth alignment marks 240 are formed
on each of the molding sections 222. The two fourth alignment marks
240 of each molding section 222 are positioned corresponding to the
two first alignment marks 130 adjacent a respective one of the
microstructures 120 of the imprinting mold 100. In the present
embodiment, the fourth alignment marks 240 are recesses defined in
the surface 210. In the present embodiment, the fourth alignment
marks 240 have the same shape as the first alignment marks 130;
that is, the fourth alignment marks 240 are cross-shaped. It can be
understood that the number and the arrangement of the fourth
alignment marks 240 can be varied according to the requirements of
practical applications. In the present embodiment, each of the
third alignment marks 230 has a larger size than each of the fourth
alignment marks 240.
[0025] In one embodiment, the first alignment marks 130, the second
alignment marks 140, the third alignment marks 230, and the fourth
alignment marks 240 are all formed by a photolithographic
process.
[0026] Referring to FIG. 5, a blob of molding material 300 is
applied to each of the molding sections 222. The molding material
300 can be, for example, epoxy resin, acrylate-based resin,
polyurethane, or polymerized siloxane.
[0027] Referring to FIG. 6, the first alignment marks 130 and the
second alignment marks 140 of the imprinting mold 100 are aligned
with the fourth alignment marks 240 and the third alignment marks
230 of one of the imprinting regions 220, respectively.
[0028] Referring to FIG. 7, the imprinting mold 100 is pressed on
the molding material 300 on the imprinting region 220, and pressed
portions of the molding material 300 are solidified with
ultraviolet (UV) light.
[0029] Referring to FIG. 8, after the pressed portions of the
molding material 300 are solidified, the imprinting mold 100 is
removed, thereby exposing a plurality of lenses 260 formed on the
imprinting region 220. Subsequently, the imprinting mold 100 is
pressed on molding material 300 on another one of the imprinting
regions 220. Then the pressed portions of the molding material 300
are solidified, and the imprinting mold 100 is removed. This
process is repeated for each other imprinting region 220. Thus, a
lens array 400 with a full plurality of all the lenses 260 is
obtained, as shown in FIG. 9.
[0030] It is to be noted that, in the process of forming a
plurality of lenses 260 on each imprinting region 220, the UV light
should be controlled to avoid solidifying unpressed portions of
molding material 300 on other imprinting regions 220 not yet
processed. It can be understood that in other embodiments, the
molding material 300 of a next imprinting region 220 to be
processed can be applied only after solidifying of the molding
material 300 of the imprinting region 220 currently being
processed.
[0031] Because the second alignment marks 140 align with the third
alignment marks 230, the imprinting mold 100 can be aligned with
each of the imprinting regions 220. At the same time, because the
first alignment marks 130 align with the fourth alignment marks
240, each molding section 222 of the imprinting region 220 can be
aligned with each of the corresponding microstructures 120 of the
imprinting mold 100. Therefore, the precision of the lens array 400
can be improved.
[0032] While certain embodiments have been described and
exemplified above, various other embodiments from the foregoing
disclosure will be apparent to those skilled in the art. The
present invention is not limited to the particular embodiments
described and exemplified, but is capable of considerable variation
and modification without departure from the scope and spirit of the
appended claims.
* * * * *