Carrier mechanism for cleaning and handling

Embodiments of the present disclosure relate to a carrier mechanism for retaining optical devices. The carrier mechanism includes adjacent tray assemblies stacked such that a plurality of optical device lenses are retained therebetween. The carrier mechanism retains the plurality of optical device lenses without damaging the plurality of optical device lenses by contacting corners of the optical device lenses. The plurality of optical device lenses are retained with a plurality of support pins and a plurality of capture pins disposed in the tray assemblies. Each tray includes a plurality of openings corresponding to the plurality of optical device lenses such that fluids may contact the plurality of optical device lenses. The carrier mechanism may be utilized in multiple processing methods of the plurality of optical device lenses.

BACKGROUND

Field

Embodiments of the present disclosure generally relate to optical devices. More specifically, embodiments described herein relate to a carrier mechanism for retaining optical devices.

Description of the Related Art

Optical devices including waveguide combiners, such as augmented reality waveguide combiners, and flat optical devices, such as metasurfaces, are used to assist in overlaying images. Generated light is propagated through an optical device until the light exits the optical device and is overlaid on the ambient environment.

The optical devices generally include structures disposed on the optical devices. The optical devices and structures formed thereon are formed from thin, brittle materials that are damaged when exposed to external stresses. Additionally, some coatings applied over the optical devices and structures formed thereon are sensitive to handling. Thus, optical devices are susceptible to damage when transferring the optical devices between different processing tools. Therefore, utilizing carrier mechanisms to retain the optical devices during a processing operation is desirable. However, carrier mechanisms require precise configurations to avoid contacting and damaging the structures, coatings, and optical devices.

Additionally, many carrier mechanisms for retaining the optical devices are generally only used for one step of a series of processing operations, leading to an increase in handling of the optical devices. For example, vertical processing and fluid based cleaning operations are difficult to perform while retaining the optical devices in carrier mechanisms. The increased handling may lead to damage to the optical devices. Accordingly, what is needed in the art is a carrier mechanism for retaining optical devices.

SUMMARY

In one embodiment, a carrier having at least two tray assemblies is provided. Each tray assembly includes a first locating rail and a first non-locating rail. Each tray assembly further includes a tray coupled to the first locating rail and the first non-locating rail. The tray is disposed between the first locating rail and the first non-locating rail. Each tray assembly further includes a plurality of openings disposed through the tray and a plurality of capture pins disposed through the tray. Each tray assembly further includes a plurality of support pins disposed through the tray, the plurality of support pins and the plurality of capture pins operable to retain a plurality of optical device lenses.

In another embodiment, a carrier having at least two tray assemblies is provided. Each tray assembly includes a first locating rail and a first non-locating rail. Each tray assembly further includes a tray coupled to the first locating rail and the first non-locating rail. The tray is disposed between the first locating rail and the first non-locating rail. Each tray assembly further includes a plurality of openings disposed through the tray and a plurality of capture pins disposed through the tray. Each tray assembly further includes a plurality of support pins disposed through the tray. The plurality of support pins and the plurality of capture pins are operable to retain a plurality of optical device lenses. The plurality of support pins include a ramp operable to contact a corner of the plurality of optical device lenses.

In yet another embodiment, a method is provided. The method includes positioning a carrier mechanism in a processing station including a fluid. The carrier mechanism is operable to retain a plurality of optical device lenses between a first tray assembly and a second tray assembly. The plurality of optical device lenses are retained by a plurality of support pins disposed in the first tray assembly and a plurality of capture pins disposed in the second tray assembly. The method further includes directing ultrasonic energy towards the carrier mechanism. The ultrasonic energy propagates parallel to a surface of the plurality of optical device lenses to be cleaned. The ultrasonic energy forces the fluid through a gap between the first tray assembly and the second tray assembly and through a plurality of openings in the first tray assembly and the second tray assembly.

DETAILED DESCRIPTION

Embodiments of the present disclosure generally relate to optical devices. More specifically, embodiments described herein relate to a carrier mechanism for retaining optical devices. In one embodiment, a carrier having at least two tray assemblies is provided. Each tray assembly includes a first locating rail and a first non-locating rail. Each tray assembly further includes a tray coupled to the first locating rail and the first non-locating rail. The tray is disposed between the first locating rail and the first non-locating rail. Each tray assembly further includes a plurality of openings disposed through the tray and a plurality of capture pins disposed through the tray. Each tray assembly further includes a plurality of support pins disposed through the tray, the plurality of support pins and the plurality of capture pins operable to retain a plurality of optical device lenses.

FIG.1Ais a schematic, perspective view of a carrier mechanism100. The carrier mechanism100includes two or more tray assemblies105i.e., a first tray assembly105A and a second tray assembly105B. Each tray assembly105includes a locating rail102, a non-locating rail104, and a tray106. The tray106may be coupled to a plurality of capture pins114and a plurality of support pins116. In one embodiment, which can be combined with other embodiments described herein, the carrier mechanism100has a carrier mechanism height120of between about 135 mm to about 323 mm. The carrier mechanism100is operable to retain a plurality of optical device lenses112. The carrier mechanism100provides for the plurality of optical device lenses112to be placed in a cleaning device, such as an ultrasonic cleaner. The carrier mechanism100allows for chemical exposure, thermal exposure, vibrations, and other fabrication steps to be applied to the plurality of optical device lenses112. Additionally, the carrier mechanism100allows for metrology processes to be performed on the plurality of optical device lenses112. For example, optical inspection or quality inspection may be performed on the plurality of optical device lenses112when retained by the carrier mechanism100. The carrier mechanism100may also be utilized to retain the plurality of optical device lenses for shipping. Although only four capture pins114and four support pins116are shown retaining each optical device lens of the plurality of optical device lenses112, any number of the plurality of support pins116and the plurality of capture pins114may be disposed in the tray106to retain the optical device lenses112as desired.

As shown inFIG.1A, two or more tray assemblies105are stacked together to form the carrier mechanism100. The carrier mechanism100includes at least the second tray assembly105B disposed on, i.e., stacked on, the first tray assembly105A. The locating rail102and non-locating rail104of the first tray assembly105A are able to be in contact with the adjacent locating rail102and non-locating rail104of the second tray assembly105B such that the two or more tray assemblies105may be stacked. The locating rail102and the non-locating rail104are formed such that the locating rail102and non-locating rail104of the first tray assembly105A are able to be overlapped with the adjacent locating rail102and non-locating rail104of the second tray assembly105B to remain stacked. In one embodiment, which can be combined with other embodiments described herein, locating pins are disposed on the locating rail102such that the two or more tray assemblies105remain overlapped and stacked. The two or more tray assemblies105may be stacked utilizing a tray feeder. Although only two tray assemblies105(the first tray assembly105A and the second tray assemblies105B) are shown inFIG.1A, the carrier mechanism100may include more than two stacked tray assemblies105. For example, the carrier mechanism100can include ten tray assemblies105in a stack.

The locating rail102and the non-locating rail104retain the tray106. The locating rail102includes a first slit108. The non-locating rail104includes a second slit109. The first slit108and the second slit109allow for the tray106to be positioned between the locating rail102and the non-locating rail104. The tray106is inserted into the first slit108of the locating rail102. The first slit108aligns the tray106within the tray assembly105. The tray106is then slid into the second slit109of the non-locating rail104. The locating rail102and the non-locating rail104are formed from materials that include, but are not limited to, stainless steel, plastic (such as polypropylene), ceramic (such as Al2O3), brass, or combinations thereof.

The tray106further includes a plurality of openings110. The plurality of openings110provide access to the plurality of optical device lenses112disposed between two stacked tray assemblies105. The shape of the plurality of openings110may be adjusted to correspond to a contour of the plurality of optical device lenses112disposed between the two stacked tray assemblies105. The tray106may be a corrosion resistant material. The tray106includes, but is not limited to, stainless steel, plastic (such as polypropylene), ceramic (such as Al2O3), brass, or combinations thereof. Although only six of the plurality of optical device lenses112are shown inFIG.1A, any number of the plurality of optical device lenses112may be retained by two adjacent tray assemblies105. Additionally, any number of the plurality of optical device lenses may be retained in the carrier mechanism100.

The plurality of openings110may be laser cut into the tray106based on the desired contour of the plurality of openings110corresponding to the plurality of optical device lenses112. The plurality of openings110allow for fluids, gases, or solids to contact the plurality of optical device lenses112. For example, a chemical bath or water batch can contact the plurality of optical device lenses112through the plurality of openings110. The fluids, gases, or solids may also contact the plurality of optical device lenses112through a gap126between the two stacked tray assemblies105. The gap126is between about 6 mm and about 12 mm. Additionally, the plurality of openings110and the gap126allows for optical inspection of the plurality of optical device lenses112.

The plurality of optical device lenses112can be any optical device lens used in the art, and can be either opaque or transparent depending on the use of the optical device lens. Additionally, optical device lens selection may further include varying shapes, thickness, and diameters of the plurality of optical device lenses112. The tray assembly105is operable to be adjusted to fit different optical device lens shapes. In one embodiment, which can be combined with other embodiments described herein, the plurality of optical device lenses112include, but are not limited to, silicon (Si), silicon dioxide (SiO2), fused silica, quartz, silicon carbide (SiC), germanium (Ge), silicon germanium (SiGe), indium phosphide (InP), gallium arsenide (GaAs), gallium nitride (GaN), sapphire, or combinations thereof. In some embodiments, which can be combined with other embodiments described herein, the plurality of optical device lenses112are flat optical devices, such as metasurfaces. In other embodiments, which can be combined with other embodiments described herein, the plurality of optical device lenses112are waveguide combiners, such as augmented reality waveguide combiners. In another embodiment, which can be combined with other embodiments described herein, the plurality of optical device lenses112can have optical device structures patterned on a first surface113or a second surface115(shown inFIG.1B) of the plurality of optical device lenses112.

FIG.1Bis a schematic, cross-sectional view of a portion125of the carrier mechanism100. The portion125is shown inFIG.1A. As seen inFIG.1B, the tray106is disposed in the second slit109of the non-locating rail104. The tray106may be held in place by setscrews122. The setscrews122are disposed in the non-locating rail104and may be tightened to contact the tray106for improved stability and retention of the tray106. The setscrews122may also be disposed in the locating rail102to retain the tray106in the first slit108.

The plurality of capture pins114and the plurality of support pins116are coupled to the tray106. The plurality of capture pins114and the plurality of support pins116are offset to prevent over-constraint of the plurality of optical device lenses112. An optical device lens of the plurality of optical device lenses112is positioned into contact with the support pin116. The plurality of support pins116each include a ramp118and a capture post117. The ramp118allows for corners of the plurality of optical device lenses112to sit on the plurality of support pins116. In one embodiment, which can be combined with other embodiments described herein, the ramp118is substantially shallow such that the corners of the plurality of optical devices are retained without moving or shifting on the ramp118. Thus, the plurality of optical device lenses112are not contacted on the edges and faces of the plurality of optical device lenses112. The ramp118allows the plurality of optical device lenses112to be retained without damaging the plurality of optical device lenses112. The capture post117prevents lateral movement of the plurality of optical device lenses112. The plurality of capture pins114provide a vertical force to retain the plurality of optical device lenses112while the plurality of support pins116prevent lateral movement of the plurality of optical device lenses112. The retention of the plurality of optical device lenses112in the carrier mechanism100by the plurality of capture pins114and the plurality of support pins116allows for the plurality of optical device lenses112to be transferred to multiple processing stations for processing. The carrier mechanism100retains the plurality of optical device lenses112securely such that additional handling is not required for the plurality of optical device lenses112. Therefore, the carrier mechanism100minimizes damage to the plurality of optical device lenses112. Additionally, the carrier mechanism100providing for multiple processing steps of the plurality of optical device lenses112increases throughput as less time is required for handling and transferring the plurality of optical device lenses112.

A ramp119of each of the plurality of capture pins114also improves lateral support of the plurality of optical device lenses112without damaging the plurality of optical device lenses112. The retention of the plurality of optical device lenses112allows for the carrier mechanism100to be utilized for processing methods such as vertical processing. The plurality of support pins116and the plurality of capture pins114include a plastic material such as polyetheretherketone, polypropylene, or other high temperature plastics.

The plurality of support pins116and the plurality of capture pins114are coupled to the tray106with a heat staking process. The plurality of support pins116and the plurality of capture pins114include a bonding region124. The bonding region124of each of the plurality of support pins116and the plurality of capture pins114is disposed through the tray106. A heat staking process is applied to the bonding region124to couple the plurality of support pins116and the plurality of capture pins114to the tray106. The heat exposure provides a bonded seal to the tray106such that the plurality of support pins116and the plurality of capture pins114are retained in the tray106. In one embodiment, which can be combined with other embodiments described herein, the bonding region124, when exposed to the heat staking process, forms a rivet and is bonded to the tray106.

FIG.1Cis a schematic, perspective view of a portion125of the carrier mechanism100. The portion125is shown inFIG.1A. As shown inFIG.1C, the plurality of capture pins114and the plurality of support pins116are offset to prevent over-constraint of the optical device lens of the plurality of optical device lenses112. The bonding region124of the plurality of support pins116and the plurality of capture pins114are disposed through the tray106. The heat staking process forms a rivet with the bonding regions124to secure the plurality of capture pins114and the plurality of support pins116to the tray106. Further, as seen inFIG.1C, fluids, i.e., cleaning fluids, may be forced through the plurality of openings110or the gap126while the plurality of optical device lenses112are retained between the trays106.

FIG.2is a schematic, cross sectional view of a processing station200. The carrier mechanism100is disposed in the processing station200. The processing station200can be configured to deliver ultrasonic energy to a plurality of optical device lenses112retained by the carrier mechanism100. The ultrasonic energy is provided by a transducer202. The processing station200allows for soaking of the carrier mechanism100in a fluid. In one embodiment, which can be combined with other embodiments described herein, the fluid is a cleaning fluid and the cleaning fluid is forced through a plurality of openings110or a gap126of the carrier mechanism to remove particles on the plurality of optical device lenses112. In some cases, the cleaning fluid includes, but is not limited to, hydrogen fluoride (HF), hydrochloric acid (HCl), nitric acid (HNO3), citric acid (C6H8O7), ammonium hydroxide (NH4OH), deionized water (DIW), or combinations thereof. In another embodiment, which can be combined with other embodiments described herein, the carrier mechanism100can be disposed on a pedestal (not shown) in the processing station200. In yet another embodiment, which can be combined with other embodiments described herein, the processing station200can be configured to deliver air flow to the plurality of optical device lenses112retained by the carrier mechanism100. For example, the air flow may be forced through the plurality of openings110or a gap126of the carrier mechanism to dry the plurality of optical device lenses112. The processing station200can also be configured to spray gases, fluids, or solids to the plurality of optical device lenses112retained by the carrier mechanism100.

The plurality of optical device lenses are retained in the carrier mechanism100by a plurality of capture pins114and a plurality of support pins116disposed in a tray106of a tray assembly105. The carrier mechanism100includes stacks of the tray assemblies105allowing for the plurality of optical device lenses112to be retained in a vertical processing position. Thus, a first surface113or a second surface115of the plurality of optical device lenses112is perpendicular to a surface204of the transducer202. The first surface113and the second surface115may have optical device structures disposed thereon. Therefore, the first surface113and the second surface115are the surfaces to be cleaned. The first surface113and the second surface115are parallel to the direction the transducer202directs ultrasonic energy, such that air pockets will not form. In other embodiments, which can be combined with other embodiments described herein, the transducer202is disposed on a sidewall206of the processing station200. Therefore, to ensure the ultrasonic energy is directed parallel to the surfaces to be cleaned of the plurality of optical device lenses112, the carrier mechanism100is positioned with the first surface113and the second surface115perpendicular to the sidewall206of the processing station200.

FIG.3is a flow diagram of a method300for retaining a plurality of optical device lenses112in a carrier mechanism100. At operation301, the plurality of optical device lenses112are positioned on a first tray assembly105A. The plurality of optical device lenses112are in contact with a plurality of support pins116disposed in a tray106of the first tray assembly105A. At operation302, a second tray assembly105B is placed over the first tray assembly105A. A plurality of capture pins114disposed in the second tray assembly105B further retain the plurality of optical device lenses112. The locating rail102and non-locating rail104of the first tray assembly105A are aligned and stacked with the locating rail102and non-locating rail104of the second tray assembly105B. The plurality of capture pins114retained in the second tray assembly105B surround the plurality of optical device lenses112disposed in the carrier mechanism100.

At optional operation303, additional tray assemblies105are stacked on the second tray assembly105B until a desired number of the plurality of optical device lenses112have been retained in the carrier mechanism100.

At optional operation304, a sub-method400is performed.FIG.4is a flow diagram of a sub-method400for processing a plurality of optical device lenses112in a carrier mechanism100. The sub-method400is described with reference to the processing station200ofFIG.2. However, the sub-method400may be performed in conjunction with other processing stations in accordance with the embodiments of the disclosure described herein. At operation401, the carrier mechanism100is positioned in a processing station200. The carrier mechanism100is positioned such that a first surface113and a second surface115of the plurality of optical device lenses112are parallel to the direction of propagation of the ultrasonic energy. The ultrasonic energy is provided by a transducer202. The ultrasonic energy forces fluid through a gap126and a plurality of openings110in the carrier mechanism100such that the fluid contacts the plurality of optical device lenses112. In one embodiment, the ultrasonic energy has a frequency of about 20 kHz to about 100 MHz. In another embodiment, which can be combined with other embodiments described herein, megasonic energy may be utilized in the operation304.

At operation402, a spray mixture is sprayed over the carrier mechanism100. The spray mixture is sprayed through the gap126and the plurality of openings110in the carrier mechanism100such that the spray mixture contacts the plurality of optical device lenses112. The spray mixture includes, but is not limited to, one or more of a gaseous CO2, liquid CO2, solid CO2, combinations thereof, or other suitable materials.

At operation403, the carrier mechanism100is exposed to a drying process. The drying process includes flowing air through the gap126between the first tray assembly105A and the second tray assembly105B and through the plurality of openings110. For example, the drying process may include directing air at the plurality of optical device lenses112to dry the plurality of optical device lenses112after prior processing steps such as the operation402. In some embodiments, which can be combined with other embodiments described herein, the drying process is performed in the processing station200of the operation402. In other embodiments, which can be combined with other embodiments described herein, the drying process performed in a separate processing station.

In another optional operation305, the carrier mechanism100may be transferred to other processing stations for additional processing steps. The carrier mechanism100provides for multiple processing steps to be performed on the plurality of optical device lenses112while retained in the carrier mechanism100. Therefore, the carrier mechanism100minimizes damage to the plurality of optical device lenses112as there is less handling of the plurality of optical device lenses112between processing steps. Additionally, the carrier mechanism100providing for multiple processing steps of the plurality of optical device lenses112increases throughput as less time is required for handling and transferring the plurality of optical device lenses112.

In summation, a carrier mechanism for retaining optical devices is shown and described herein. The carrier mechanism includes adjacent tray assemblies stacked such that a plurality of optical device lenses are retained therebetween. The tray assembly includes a locating rail, a non-locating rail, and a tray retained by the locating rail and the non-locating rail. The tray includes a plurality of capture pins and a plurality of support pins disposed therethrough. The plurality of capture pins and plurality of support pins retain the plurality of optical device lenses without contacting or damaging the plurality of optical device lenses by contacting corners of the optical device lenses. Each tray includes a plurality of openings corresponding to the plurality of optical device lenses such that fluids may contact the plurality of optical device lenses. Additionally, the plurality of openings provide for optical inspection of the plurality of optical device lenses. The carrier mechanism is operable to be utilized in multiple processing methods and therefore minimizes damage to the plurality of optical device lenses and increases throughput.

While the foregoing is directed to examples of the present disclosure, other and further examples of the disclosure may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.