# US 8,570,669 B2 · Multi-layer polymer lens and method of making same

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- Number: US 8,570,669 B2
- Document ID: US8570669B2
- Status: Granted
- Kind: B2
- Application number: 13/356,328
- Filed: 2012-01-23
- Published: 2013-07-25
- Granted: 2013-10-29
- Earliest claimed: 2012-01-23
- Assignees: Optiz, Inc.
- Applicants: Vage Oganesian
- Inventors: Vage Oganesian
- Web page: https://patentgrep.com/patent/US8570669B2

## CPC

- G02B 7/025: {using glue}
- B29D 11/00278: {Lenticular sheets (B29D11/00269 takes precedence)}
- B29D 11/0073: {Optical laminates}
- G02B 3/0012: {characterised by the manufacturing method}
- G02B 13/0085: {employing wafer level optics}
- H10F 39/804: {Containers or encapsulations}
- H10W 72/90: Bond pads, in general
- H10W 72/536: {the connected ends being ball-shaped}
- H10W 72/59: Bond pads specially adapted therefor
- G02B: OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00)
- H10F: INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION
- H10W: GENERIC PACKAGES, INTERCONNECTIONS, CONNECTORS OR OTHER CONSTRUCTIONAL DETAILS OF DEVICES COVERED BY CLASS H10

## Abstract

A multi-layered lens having a substrate with opposing first and second surfaces. The substrate is formed of a plurality of discrete 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

### Claim 1

A lens, comprising:
a substrate having opposing first and second surfaces, wherein the substrate is formed of a plurality of discrete 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.

### Claim 2 (depends on 1)

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.

### Claim 3 (depends on 1)

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

### Claim 4 (depends on 1)

The lens of claim 1, further comprising:
a plurality of alignment marks formed at one of the first and second surfaces.

### Claim 5 (depends on 4)

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

### Claim 6 (depends on 4)

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

### Claim 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.

### Claim 8 (depends on 7)

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

### Claim 9 (depends on 7)

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.

### Claim 10 (depends on 7)

The method of claim 7, further comprising;
filling the first cavity with a material before the forming of the second polymer layer.

### Claim 11 (depends on 7)

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.

### Claim 12 (depends on 11)

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

### Claim 13 (depends on 7)

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.

### Claim 14 (depends on 13)

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.

### Claim 15 (depends on 13)

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.

### Claim 16 (depends on 13)

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.

### Claim 17 (depends on 13)

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.

### Claim 18 (depends on 17)

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

### Claim 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.

### Claim 20 (depends on 19)

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

### Claim 21 (depends on 19)

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.

### Claim 22 (depends on 21)

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

### Claim 23 (depends on 19)

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.

### Claim 24 (depends on 23)

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.

### Claim 25 (depends on 23)

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.

### Claim 26 (depends on 25)

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

### Claim 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 discrete 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.

### Claim 28 (depends on 27)

The lens assembly of claim 27, wherein:
the outer edges of the substrates are round; and
the layer of material is cylindrical in shape.

### Claim 29 (depends on 27)

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

### Claim 30 (depends on 27)

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.

### Claim 31 (depends on 27)

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.

### Claim 32 (depends on 27)

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.