Optical Sensing Products Daicel's wafer-level lenses are made with our proprietary transparent epoxy resin featuring high heat resistance. They can be applied to parts mounted with the reflow process.
What is a wafer-level lens?
Several lenses can be manufactured at one time from a wafer-like resin and cut to shape.
While conventional injection molding can produce only a few dozen lenses at one time, we can produce hundreds of wafer-level lenses at a time. Amenable to mass production, the wafer-level lens process offers the significant advantage of being able to make lenses in a multitude of shapes, thicknesses, and sizes, surpassing the capabilities of injection molding.
In addition to the process advantages, the lens material itself is a heat-resistant resin developed by Daicel that can be used in the reflow process.
High heat resistance
Our unique and highly heat-resistant material has excellent resistance to reflow temperatures. The transparency and shape of the lens is unaffected by exposure to reflow process temperatures as high as 260℃.
Conventional plastic molding is limited to a minimum thicknesses of 200-300 microns, but depending on the shape, our process can produce ultra-thin lenses measuring only 50 microns or less.
We can also mass-produce ultra-small stacked lens units measuring 0.5 mm square by taking advantage of the wafer-level lens process.
With the wafer-level lens process, lenses can be molded to submicron size, with sharp tips, and with extremely fine prism lenses. Even lenses of uneven thickness can be produced. What's more, lenses with ultra-fine nano-scale patterns can be formed.
The Molding Process
We use our proprietary epoxy resins and silicone resins to meet customer performance requirements and offer solutions that combine optical design and peripheral technologies. Daicel's unique imprint molding technology contributes to efficient production of high-precision wafer-level lenses. We can also offer surface decoration and integral molding at levels of precision ranging from micro scale to nano scale.
Our wafer-level lenses also feature excellent resistance to the heat of solder flow and are compatible with electronic component mounting. "Imprint molding" is a processing technology in which a thermosetting or photo-curable resin is sandwiched between molds, and the pattern is transferred. The surface shape engraved in the imprint mold can be transferred directly to the resin with great accuracy. Our core technologies include material design technology, molding technology, and two- and three-dimensional evaluation and analysis technologies for molded products. These technologies enable us to produce high-precision lenses efficiently.
- Batch bonding of wafer-level lenses and substrates
- No need to adjust focus during camera assembly.
- Provision of products with new functions through direct processing of wafer lenses