Metalens-Integrated Optical Engine for Compact Beam Combining
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Solution Overview
Problem
Conventional optical engines are limited in size reduction due to large collimating lenses and beam splitters, and maintaining high precision in assembly is challenging, hindering their application in smaller form factors required for augmented reality, virtual reality, and micro projection.
Innovation Solution
A metalens-integrated optical engine utilizing meta optical members for collimating, deflecting, and combining light beams, with nanostructures arranged in arrays to achieve precise beam control and reduce component count, employing semiconductor fabrication for high precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional collimating lenses and beam splitters are used, then optical function is achieved, but device size is large
Solution Approach 1:
The patent combines multiple optical functions (collimation, deflection, and beam combining) into a single integrated metalens component. The metalens integrates the collimating lens and beam splitter functions that were previously separate components, thereby reducing the overall device volume while maintaining optical performance.
Solution Approach 2:
The patent replaces conventional mechanical optical components (glass lenses and beam splitters) with a metalens based on metasurface technology. This substitution enables miniaturization by using sub-wavelength structures that can be fabricated with modern semiconductor processes, achieving the desired optical functions in a much smaller form factor.
2Volume of moving object
If component size is reduced, then optical engine size is reduced, but manufacturing precision becomes difficult to maintain
Solution Approach 1:
The metalens is fabricated using semiconductor manufacturing processes rather than traditional optical machining. This allows for precise control of nanostructure dimensions and positions through photolithography and etching, achieving manufacturing precision at the nanoscale that is difficult to attain with conventional mechanical methods for small optical components.
Solution Approach 2:
The patent designs the metalens with specific geometric parameters (nanostructure height, width, and spacing) that are optimized for fabrication using standard semiconductor processes. By adjusting these parameters, the design achieves both miniaturization and manufacturability, allowing precise control over the optical properties while remaining compatible with existing manufacturing infrastructure.
3Volume of moving object
If distances among light sources are reduced, then optical engine size is reduced, but positioning precision requirement increases
Solution Approach 1:
The metalens integrates the functions of multiple optical components into a single element, eliminating the need for precise relative positioning between separate collimating lenses and beam splitters. The integrated structure inherently defines its own optical path, removing the positioning precision requirements that would otherwise arise from assembling multiple components at reduced distances.
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 reduces the size and enhances precision of optical engines, enabling applications in augmented reality, virtual reality, and micro projection by minimizing component size and improving manufacturing and assembly precision.
Implementation Method 1
The collimating and deflecting module includes a plurality of collimating and deflecting meta optical members each of which is located on the path of the light beam emitted by a respective one of the light source modules. The collimating and deflecting meta optical members is for collimating and deflecting the light beams emitted by the light source modules such that the light beams emitted by the light source modules are collimated and deflected and travel to a predetermined position.
Implementation Method 2
Each of the collimating and deflecting meta optical members includes a substrate that has a surface extending along an X-axis and a Y-axis, and a collimating and deflecting meta optical array that is disposed on the surface, that permits incidence of the light beams emitted by the respective one of the light source modules, and that includes a plurality of nanostructures arranged in an array.
Implementation Method 3
The light-combining module includes a light-combining meta optical member that is located at one side of the collimating and deflecting module opposite to the light source modules. The light-combining meta optical member includes a light-combining meta optical array that is located at the predetermined position, that receives the light beams collimated and deflected via the collimating and deflecting module, and that deflects the light beams based on wavelengths and angles of incidence, so as to combine the non-parallel light beams into a single light beam.
Implementation Method 4
The nanostructures of the collimating and deflecting meta optical array of n-th collimating and deflecting meta optical member satisfy a phase shift formula relative to a center of an optical axis: ΔφnC(xn,yn) = -2π/λn * (xn²/2ƒxcn + yn²/2ƒycn) - 2π/λn * ΔΦnC(xn,yn), where λn is the wavelength of n-th light beam, ƒxcn is the focal length of the collimating and deflecting meta optical array along the X-axis, ƒycn is the focal length of the collimating and deflecting meta optical array along the Y-axis, and ΔΦnC(xn,yn) is high-order term for compensating the phase shift of high-order optical aberration.
Data Source
AI summary
A metalens-integrated optical engine includes a plurality of light source modules, a collimating and deflecting module and a light-combining module. Each of the light source modules emits a light beam. The collimating and deflecting meta optical members is for collimating and deflecting the light beams such that the light beams are collimated and deflected and travel to a predetermined position. The light-combining module includes a light-combining meta optical array that is located at the predetermined position, that receives the light beams via the collimating and deflecting module, and that deflects the light beams, so as to combine the non-parallel light beams into a single light beam.