Recessed optical surfaces
View Patent ↗An optics block includes a substrate having first and second opposing surfaces, the substrate being a first material, a plurality of through holes extending in the substrate between the first and second opposing surface, a second material, different than the first material, filling a portion of the through holes and extending on a portion of the first surface of the substrate outside the through holes, and a first lens structure in the second material and corresponding to each of the through holes.
1. An optics block, comprising:
a substrate having first and second opposing surfaces, the substrate being a first material;
a plurality of through holes extending in the substrate between the first and second opposing surfaces;
a second material, different than the first material, filling a portion of the through holes and extending on a portion of the first surface of the substrate outside the through holes;
a first lens structure in the second material and corresponding to each of the through hole; and
a third material, different than the first material, extending on a portion of the second surface of the substrate outside the through holes and covering the through holes.
2. The optics block as claimed in claim 1 , wherein the first material is opaque and/or dispersive.
3. The optics block as claimed in claim 1 , wherein the substrate is a mesh.
4. The optics block as claimed in claim 1 , wherein sidewalls of the through holes are planar.
5. The optics block as claimed in claim 1 , wherein sidewalls of the through holes are angled and extend along a continuous angle.
6. The optics block as claimed in claim 1 , wherein the first material has a Young's modulus of less than 20.
7. The optics block as claimed in claim 1 , wherein the second material and the third material together completely fill the through holes.
8. The optics block as claimed in claim 7 , wherein the second and third material completely cover the first and second surfaces of the substrate, respectively.
9. The optics block as claimed in claim 8 , wherein the second and third materials are the same.
10. The optics block as claimed in claim 8 , wherein the first lens structure includes a first lens surface adjacent the first surface of the first substrate and in the second material and a second lens surface adjacent the second surface of the first substrate and in the third material.
11. The optics block as claimed in claim 10 , further comprising aperture stops between the second and third materials, the aperture stops partially extending into the through holes.
12. The optics block as claimed in claim 10 , wherein the second and third materials are the same.
13. The optics block as claimed in claim 12 , further comprising an interface between the second and third materials.
14. A method of forming an optics block, comprising:
providing a substrate having first and second opposing surfaces, the substrate being a first material and having a plurality of through holes extending in the substrate between the first and second opposing surfaces;
providing a second material, different than the first material, filling a portion of the through holes and extending on a portion of the first surface of the substrate outside the through holes, providing the second material includes encapsulating the substrate with the second material; and
replicating a first lens structure in the second material and corresponding to each of the through holes.
15. A method of forming an optics block, comprising:
providing a substrate having first and second opposing surfaces, the substrate being a first material and having a plurality of through holes extending in the substrate between the first and second opposing surfaces;
providing a second material, different than the first material, filling a portion of the through holes and extending on a portion of the first surface of the substrate outside the through holes;
replicating a first lens structure in the second material and corresponding to each of the through holes; and
providing a third material, different than the first material, extending on a portion of the second surface of the substrate outside the through holes and covering the through holes.
16. The method as claimed in claim 15 , wherein the second material and the third material together completely fill the through holes.
17. The method as claimed in claim 16 , wherein the second and third material cover the first and second surfaces of the substrate, respectively.
18. The method as claimed in claim 17 , wherein the second and third materials are the same.
19. The method as claimed in claim 17 , wherein providing the third material occurs before providing the second material.
20. The method as claimed in claim 19 , wherein the third material includes a second lens structure covering the through holes.
21. The method as claimed in claim 20 , further comprising, before providing the third material, forming aperture stops adjacent the second lens structures on the third material.
22. The method as claimed in claim 17 , wherein replicating the first lens structure includes replicating a first lens surface adjacent the first surface and in the second material and replicating a second lens surface adjacent the second surface and in the third material.
23. The method as claimed in claim 22 , wherein replicating the first and second lens surfaces is simultaneous.
24. The method as claimed in claim 22 , wherein replicating the first and second lens surfaces is sequential.
25. An optics block, comprising:
a substrate having first and second opposing surfaces, the substrate being a first material;
a plurality of through holes extending in the substrate between the first and second opposing surfaces;
a second material, different than the first material, the second material encapsulating the substrate; and
a first lens structure in the second material and corresponding to each of the through hole.