Diffractive Optical Element for Structured Line Focus
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Solution Overview
Problem
Existing methods for generating a line focus for material processing, such as those used in OLED display production, suffer from high power loss and inefficiency due to the use of masks and projection lenses, as well as issues like speckle formation and sensitivity to adjustment errors in diffuser and beam shaper principles.
Innovation Solution
The implementation of beam shaping optics with a beam splitter function that generates the desired structuring directly, eliminating the need for projection optics and maximizing light yield in the processing plane, using diffractive optical elements to create an intensity-structured line focus with high homogeneity and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a mask and projection lens are used to generate structured line focus, then the desired intensity distribution can be achieved, but high power loss occurs in the mask plane and the overall length increases
Solution Approach 1:
The patent combines the mask function and projection lens function into a single diffractive optical element (DOE). The DOE directly generates the structured line focus pattern without requiring separate masking and projection components, thereby eliminating power loss in the mask plane and reducing the overall optical path length while maintaining the desired intensity distribution
Solution Approach 2:
The diffractive optical element performs multiple functions simultaneously: it acts as both the mask that defines the intensity distribution and the projection lens that focuses the light into a line focus. This multi-functional design eliminates the need for separate components and reduces energy loss
2Ease of operation
If a diffuser is used to generate line focus, then the far-field distribution is formed through diffraction, but speckle occurs leading to strong intensity fluctuations
Solution Approach 1:
The patent changes the fundamental parameter of how the diffuser/DOE generates the line focus. Instead of relying on far-field diffraction from each sub-area (which causes speckle), the DOE is designed to directly form the structured line focus in the near field through carefully engineered diffraction patterns, eliminating speckle while maintaining adjustment insensitivity
Solution Approach 2:
The diffractive optical element is pre-designed with specific phase and amplitude modulations that directly encode the desired line focus intensity distribution. This preliminary encoding of the target pattern into the DOE structure eliminates the need for far-field diffraction and prevents speckle formation from the outset
3Manufacturing precision
If a beam shaper with DOE is used, then good line homogeneity is achieved without speckle, but sensitive adjustment and susceptibility to light source fluctuations occur
Solution Approach 1:
The diffractive optical element is pre-configured with the exact phase and amplitude distributions needed to generate the structured line focus directly. This preliminary encoding of the optimal beam shape into the DOE structure eliminates the need for sensitive post-alignment adjustments and makes the system robust against light source fluctuations
4Manufacturing precision
If mask and projection optics are used, then structured line focus is generated, but the arrangement becomes inefficient due to light loss in the mask plane
Solution Approach 1:
The patent merges the mask and projection optics into a single diffractive optical element that directly generates the structured line focus. This integration eliminates the mask plane where light is lost, thereby maximizing light yield and improving productivity while maintaining the desired target structuring
Solution Approach 2:
The patent extracts and eliminates the inefficient mask component from the optical system. By removing the separate mask and its associated projection optics, the system eliminates the source of light loss in the mask plane while retaining the essential function of generating structured line focus through the integrated DOE
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 approach allows for high-resolution, efficient material processing with reduced light loss and improved homogeneity, enabling the production of small but high-resolution displays like those for mobile devices, and reduces the need for high-powered lasers by optimizing light distribution.
Implementation Method 1
The diffractive element (DOE), designed as a diffractive optical element (DOE), forms the desired intensity distribution in the far field, for example a line focus, through diffraction on diffractive structures
Data Source
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AI summary
The invention relates to an arrangement for generating a light beam for material processing, having a light source (1) emitting a light beam (11), a beam shaping lens (14) disposed downstream of the light source (1) and imaging the light beam (11) in a processing plane (7) at a predetermined target structure, wherein the beam shaping optic (14) comprises a beam dividing function for generating the target structure.