Bonded Multilayer Diffractive Optical Element for Chromatic Aberration Correction
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Solution Overview
Problem
Conventional diffractive optical elements face challenges in achieving high optical performance due to microscopic irregularities on the surface of UV-curable resin layers, which affect the optical characteristics and are difficult to manufacture efficiently, especially in multilayer structures where precise alignment and different refractive indices are required.
Innovation Solution
A bonded-multilayer diffractive optical element is designed with a relief pattern formed on a first optical component, bonded to a second component with a different refractive index, and sandwiched between third and fourth optical components, ensuring air-tight bonding to minimize irregularities and optimize refractive power distribution, allowing for better chromatic aberration correction and manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If UV-curable resin is used to form the diffractive optical element, then manufacturing efficiency and mass-productivity are improved, but microscopic irregularities form on the surface affecting optical characteristics
Solution Approach 1:
A flat plate is introduced as an intermediary component between the UV-curable resin and the mold. The mold contacts the flat plate surface rather than the resin surface directly, preventing microscopic irregularities from forming on the resin. This mediator allows the resin to be cured efficiently while maintaining surface flatness for optimal optical performance.
Solution Approach 2:
The invention creates a flat reference surface (the flat plate) that copies the ideal mold surface geometry. Instead of requiring the resin to directly replicate the mold surface (which causes irregularities), the flat plate provides a perfect flat surface that ensures uniform contact and prevents deformation of the resin layer.
2Reliability
If multilayer structure with different refractive indices is used, then chromatic aberration correction is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
Multiple functional components (diffractive optical element with relief pattern, flat plate for surface flatness, and curved plates for chromatic aberration correction) are merged into a single integrated multilayer structure. This combination achieves chromatic aberration correction while maintaining manufacturing efficiency through unified construction rather than separate assemblies.
Solution Approach 2:
The invention uses composite structure combining multiple UV-curable resin layers with different refractive indices. Each layer serves a specific optical function: the first layer provides the diffractive relief pattern, while subsequent layers with different refractive indices correct chromatic aberrations, creating a composite optical system with superior performance.
3Manufacturing precision
If surface irregularities are reduced, then optical characteristics are improved, but manufacturing process complexity increases
Solution Approach 1:
The flat plate serves as a mediator that simplifies the manufacturing process while ensuring surface flatness. Instead of requiring complex control of resin curing or mold surface preparation, the flat plate provides a straightforward solution: place it between the mold and resin, apply uniform pressure, and achieve flat surfaces without intricate process adjustments.
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
The solution results in a compact, lightweight diffractive optical element with improved diffraction efficiency across a wide wavelength range, reduced chromatic aberration, and simplified manufacturing, making it suitable for high-performance observation and imaging systems while reducing manufacturing costs.
Implementation Method 1
a relief pattern for generating a desired diffraction effect is formed
Implementation Method 2
the first and second optical element components comprise a relatively high refractive index and low dispersion material, and a relatively low refractive index and high dispersion material
Data Source
AI summary
A diffractive optical element 10 is constituted by sandwiching and closely bonding first and second optical element components 13, 14 which have different refractive indices and are adhered via a relief pattern 20, between third and fourth optical element components 11, 12.