Flexible Membrane Transfer for Optical Elements on Curved Surfaces

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Solution Overview

Problem

Conventional methods face challenges in creating polarization volume holograms and geometric phase optical elements on non-rigid and non-flat surfaces, limiting their applications in optics such as beam steering and display technologies.

Innovation Solution

The method involves coupling a flexible membrane with a geometric phase or polarization volume hologram optical element to a target substrate, allowing for the transfer and attachment of these elements onto flexible or curved surfaces using optically clear adhesives, enabling the creation of optical assemblies with unique optical properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If polarization volume holograms and geometric phase optical elements are prepared on rigid and flat surfaces using conventional methods, then manufacturing precision and reliability are maintained, but adaptability to non-rigid and non-flat surfaces is limited

Engineering Contradiction:

Improveadaptability to non-rigid and non-flat surfacesVSAvoidpreparation precision on non-flat surfaces

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent divides the optical element fabrication process into separate stages: first fabricating the optical element on a rigid flat substrate with high precision, then transferring it to a flexible non-flat substrate. This segmentation allows each stage to optimize for its specific requirements - precision during fabrication and flexibility during application.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent uses a flexible membrane as an intermediary carrier between the rigid fabrication substrate and the final non-flat application surface. The membrane temporarily holds the optical element during transfer, enabling the element to be moved from a rigid manufacturing environment to a flexible deployment environment without compromising its integrity or performance.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If conventional rigid substrate methods are used for optical element fabrication, then manufacturing precision is maintained, but ease of operation and application flexibility are reduced

Engineering Contradiction:

Improveapplication flexibility to curved surfacesVSAvoidfabrication complexity on flexible substrates

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

The patent performs preliminary fabrication of the optical element on a rigid substrate where manufacturing conditions are optimal and well-established. This preliminary action on a stable platform ensures high manufacturing precision, and only after successful fabrication does the transfer process begin, simplifying the overall manufacturing workflow.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The flexible membrane serves as a mediator that decouples the fabrication process from the application environment. By using this intermediary, the complex task of fabricating directly on flexible substrates is avoided, while still achieving the desired application flexibility on curved and non-flat surfaces.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If optical elements are directly fabricated on flexible substrates, then adaptability to non-rigid surfaces is improved, but manufacturing precision and optical quality deteriorate

Engineering Contradiction:

Improveflexibility and stretchability of optical assemblyVSAvoidoptical element quality on flexible substrates

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent segments the optical system into three distinct components: the rigid fabrication substrate, the flexible membrane carrier, and the final flexible application substrate. This segmentation allows the optical element to be manufactured with high precision on the rigid substrate while the flexibility requirements are met by the membrane and application substrate, which do not interfere with the optical quality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The flexible membrane acts as an intermediary that preserves the optical element's quality from the rigid fabrication substrate while enabling flexibility for the final application. The membrane's optical clarity and mechanical flexibility allow it to transmit light effectively while accommodating curved and stretched configurations.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS11808917B2Assemblies of anisotropic optical elements and methods of making

Publication Date: 2023.11.07 META PLATFORMS TECHNOLOGIES LLC

AI summary

An optical assembly includes a first flexible membrane and a first optical element coupled with at least a first portion of the first flexible membrane. The optical assembly also includes a substrate having a curved surface. The first optical element is coupled to the curved surface of the substrate with the first flexible membrane. A method for making an optical assembly includes obtaining a first flexible membrane and a first optical element. The method includes coupling the first optical element with at least a first portion of the first flexible membrane and coupling, with the first flexible membrane, the first optical element to a curved surface of a substrate.