Beamforming Vacuum Cell Using Monolithic Prism Stacks
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Solution Overview
Problem
Existing vacuum technologies face challenges in downsizing optical instruments due to the limitations of classical beamformers, such as lenses, which consume significant space and increase costs, especially when scaling down to millimeter-range dimensions, and alternative solutions like diffraction gratings are sensitive to misalignments and temperature changes.
Innovation Solution
The development of a beamformer formed from a stack of transparent sheets with partially or completely reflective coatings, where each sheet is diced and polished to create monolithic prisms, allowing for compact and efficient beam splitting with adjustable reflectivities, enabling the formation of millimeter-range beamsplitters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If classical beamformers (lenses) are used, then beam forming capability is achieved, but volume and mass of optical components increase
Solution Approach 1:
The patent divides the beam forming function into multiple discrete beamsplitters arranged in a specific geometric configuration. Instead of using a single complex lens, the system segments the optical path into multiple simpler components (beamsplitters) that collectively achieve the desired beam transformation, thereby reducing the volume and mass of individual optical elements while maintaining beam forming capability
Solution Approach 2:
The patent combines multiple beamsplitters into an integrated beam forming assembly where the individual components work together synergistically. By merging these simpler components into a coordinated system, the overall volume and mass are reduced compared to traditional single-lens beamformers, while the combined functionality achieves the required beam shaping and directing capabilities
2Area of moving object
If multiple cubical beamsplitters are used to achieve beam expansion, then beam width increases, but mass of optics scales unfavorably
Solution Approach 1:
The patent employs thin-film reflective coatings on the beamsplitter surfaces instead of bulk optical elements. These thin film layers provide the necessary optical functionality (beam splitting and directing) with minimal added mass, allowing beam width expansion without the unfavorable mass scaling that would occur with traditional cubical beamsplitters
Solution Approach 2:
The patent arranges beamsplitters in a three-dimensional geometric configuration rather than simply stacking them linearly. This spatial arrangement in multiple dimensions allows for efficient beam expansion and redistribution, achieving increased beam width with optimized mass distribution and reduced overall optical component mass compared to conventional approaches
3Area of moving object
If diffraction gratings are used for beam expansion, then beam width increases, but sensitivity to misalignments and temperature changes increases
Solution Approach 1:
The patent replaces the diffraction grating mechanism with a geometric optics-based beamsplitter array system. This substitution eliminates the sensitivity issues inherent in diffraction gratings (misalignment and temperature sensitivity) by using simple reflective surfaces with fixed geometric relationships, providing more robust and reliable beam expansion functionality
Solution Approach 2:
The patent optimizes the geometric parameters (angles, spacing, and arrangement) of the beamsplitter configuration to achieve stable beam expansion performance. By carefully selecting and maintaining these geometric parameters, the system achieves beam width expansion while minimizing sensitivity to environmental variations and alignment tolerances
4Volume of moving object
If beam splitters are used instead of lenses, then volume of optical components decreases, but manufacturing complexity increases at millimeter dimensions
Solution Approach 1:
The patent segments the beam forming function into standardized beamsplitter units that can be manufactured using conventional techniques and then assembled into the final configuration. This segmentation allows each component to be manufactured independently at millimeter dimensions with standard processes, avoiding the need for complex single-piece manufacturing while achieving compact overall volume
Solution Approach 2:
The patent designs the beamsplitter components with universal geometries and mounting interfaces that can be replicated and assembled in various configurations. This universality simplifies manufacturing by allowing standardized production of identical or similar components that can be interchangeably assembled, reducing overall manufacturing complexity despite the small dimensions
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution reduces the volume and mass of optical components, enhances manufacturability, and lowers costs by allowing for scalable and efficient beam expansion with minimal volume consumption, while maintaining superior output beam specifications and ease of assembly.
Implementation Method 1
The interface between the prisms, which forms a planar diagonal of the cube, can be partially reflective and partially transmissive
Implementation Method 2
A beam entering one face of the cube can be split into two beams
Data Source
AI summary
Beamformers are formed (e.g., carved) from a stack of transparent sheets. A rear face of each sheet has a reflective coating. The reflectivities of the coatings vary monotonically with sheet position within the stack. The sheets are tilted relative to the intended direction of an input beam and then bonded to form the stack. The carving can include dicing the stack to yield stacklets, and polishing the stacklets to form beamformers. Each beamformer is thus a stack of beamsplitters, including a front beamsplitter in the form of a triangular or trapezoidal prism, and one or more beamsplitters in the form of rhomboid prisms. In use, a beamformer forms an output beam from an input beam. More specifically, the beamformer splits an input beam into plural output beam components that collectively constitute an output beam that differs in cross section from the input beam.