Macro-Scale Pyramidal Structures for Straylight Suppression

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Solution Overview

Problem

Optically absorptive materials and coatings used in optical systems are limited by varying absorption levels with angle and wavelength, leading to inefficiencies in straylight suppression, as they can act as good diffusers at one wavelength but not others, and absorption decreases with increasing angle from perpendicular.

Innovation Solution

The implementation of macro-scale structures with optically absorptive surfaces and multiple facets or curved faces that redirect incident light between neighboring elements, maximizing surface interactions to reduce scattering and reflection, using materials like Carbon Nanotube coatings and 3D printing techniques for fabrication.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional optically absorptive materials and coatings are used, then the structure is simple and easy to manufacture, but absorption decreases with increasing angle from perpendicular and varies with wavelength

Engineering Contradiction:

Improveoptical absorption consistencyVSAvoidsurface structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The surface is segmented into multiple discrete macro-scale pyramidal features arranged in an array. Each pyramid acts as an independent light-trapping element, dividing the overall absorption function into multiple localized segments that collectively achieve omnidirectional performance

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The pyramidal features utilize curved or faceted surfaces instead of flat planes. The slanted sides of the pyramids and their curved faces enable continuous redirection of light rays at multiple angles, maintaining absorption effectiveness across varying incident angles and wavelengths

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Reliability

If flat optically absorptive surfaces are used, then manufacturing is simple, but straylight suppression is insufficient at oblique angles

Engineering Contradiction:

Improvestraylight suppression effectivenessVSAvoidfabrication complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The solution transitions from two-dimensional flat surfaces to three-dimensional pyramidal structures. This dimensional change introduces vertical and angular components that enable light redirection and multiple bounces, significantly improving straylight suppression at oblique angles while maintaining manufacturability through techniques like 3D printing and ceramic molding

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Adaptability or versatility

If macro-scale pyramidal features with optically absorptive surfaces are used, then absorption is maintained across various angles and wavelengths, but manufacturing complexity increases

Engineering Contradiction:

Improveangular and wavelength independenceVSAvoidfabrication process complexity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The structure combines macro-scale pyramidal geometry with micro-scale optically absorptive coatings or materials on the surfaces. This composite approach integrates structural light-trapping features with material-based absorption properties, achieving broad angular and wavelength independence while allowing each component to be optimized separately for manufacturability

Inventive Principle:

Principle #40Composite materials

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 enhances straylight suppression by increasing optical absorption and reducing reflection and scattering across various wavelengths and angles, creating an effective optically black surface that improves noise reduction in optical devices.

Implementation Method 1

macro-scale surfaces at different surface orientations that are slanted with respect to the supporting surface to redirect light incident towards the supporting surface towards neighboring macro structures to cause redirected light to bounce between macro-scale surfaces

Methodology Applied

Scientific EffectSpecular reflection: Reflection

Implementation Method 2

each macro-scale surface on the macro structures is structured to be optically absorptive to further reduce scattering or reflection of incident light

Methodology Applied

Scientific EffectOptical absorption: Absorption (EM radiation)

Data Source

PatentUS11209577B2Macro-scale features for optically black surfaces and straylight suppression

Publication Date: 2021.12.28 OCEAN OPTICS INC

AI summary

Improved optically absorptive surfaces as well as surfaces and structures exhibiting reduced or minimized optical scattering or reflection, including an improved optically black surface that can be used for stray light suppression having macroscopic repetitive features with multiple facets and/or curved faces that direct near specular rays and scattered rays from one feature element to neighboring elements.