Free-Form Master Lens Surface Profile Derivation
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Solution Overview
Problem
Current methods for manufacturing liquid-crystal-based planar optical components, such as diffraction or polarization gratings and lenses, are limited by the inability to record the optical function of free-form master lenses, restricting their widespread use due to deviations in the recorded optical function compared to the desired function.
Innovation Solution
A method for deriving a surface profile of a free-form master lens that compensates for deviations by determining phase differences between the desired and actual optical functions, allowing for the correction of the surface profile to achieve the desired optical function, enabling the manufacturing of planar optical components with the same or substantially the same optical function as the free-form master lens.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a free-form test lens is used for holographic patterning, then the manufacturing flexibility and optical function customization are improved, but the recorded optical function deviates from the desired function
Solution Approach 1:
The patent applies preliminary action by calculating and compensating for optical deviations before the actual holographic patterning process. The method computes the deviation between desired and actual optical functions in advance, then uses this information to pre-correct the master lens surface profile or adjust patterning parameters, ensuring accurate optical function recording from the first attempt rather than through trial-and-error iterations.
2Ease of manufacture
If conventional spherical master lenses are used, then the manufacturing process is simple and well-established, but the optical function recording is limited and cannot achieve free-form optical functions
Solution Approach 1:
The patent applies parameter changes by transitioning from spherical to free-form master lens surface profiles. This fundamental parameter change in lens geometry enables the recording of free-form optical functions that cannot be achieved with conventional spherical lenses, while the underlying holographic patterning process remains substantially unchanged, maintaining manufacturing simplicity.
3Manufacturing precision
If trial and error testing is performed to achieve desired optical function, then the optical function accuracy can be improved, but the production time and cost increase significantly
Solution Approach 1:
The patent applies feedback by implementing a computational model that predicts the deviation between desired and actual optical functions based on the master lens surface profile and patterning parameters. This feedback mechanism allows for real-time calculation and correction of deviations, eliminating the need for physical trial-and-error testing and enabling first-pass accuracy in optical function recording.
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 the cost- and time-efficient production of free-form master lenses, reducing the need for trial and error and enabling their use in various applications like optical communication systems and virtual reality glasses, by accurately replicating the desired optical function onto photo-alignment layers.
Implementation Method 1
The patterning of these photo-alignment layers is typically done by means of holographic patterning. Holographic patterning uses two circularly polarized light beams such as laser beams to illuminate the photo-alignment layers.
Implementation Method 2
The photo-alignment layers contain photo-sensitive material whose molecules change their orientation when being illuminated with light, for example, visible light or UV light which in turn causes the molecules of the liquid-crystal material to follow their orientation alignment.
Implementation Method 3
the liquid-crystal material deposited on top of the patterned photo-alignment layer deflects the incident light beam. In other words, the pattern photo-alignment layer defines the optical function of the optical component.
Data Source
AI summary
A method is provided for deriving a surface profile of a free-form master lens for patterning one or two photo-alignment layers of a planar optical component. The method includes obtaining a desired optical function of the planar optical component; and obtaining an actual optical function of the planar optical component, the actual optical function being described as recorded using a free-form test lens with a surface profile configured to provide the desired optical function. The method includes estimating a deviation between the desired optical function and the actual optical function; and correcting the surface profile of the free-form test lens using the estimated deviation, thereby deriving a surface profile for the free-form master lens.