Modular Master Hologram Layout for Flexible Multi-Face Replication
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Solution Overview
Problem
Existing methods for replicating holograms are inefficient, costly, and lack flexibility, particularly when dealing with large or diverse holograms, leading to material waste, optical disturbances, and difficulty in handling and exchanging master holograms.
Innovation Solution
A method involving a multiplicity of master elements with detachable lamination on a carrier means, allowing horizontal alignment and exposure from multiple faces, enabling precise and flexible replication of various holograms without material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a single large master element is used for replication, then the replication area is increased, but the weight and handling difficulty increase significantly
Solution Approach 1:
The patent divides a large replication area into multiple smaller master elements (e.g., 10x10 cm or 20x20 cm) that can be individually handled and exchanged. These segmented master elements are arranged on a carrier means to cover the required replication area, combining the benefits of large-area replication with manageable individual component weights.
Solution Approach 2:
Multiple master elements are nested or arranged on a common carrier means structure, allowing them to be stored and transported in a compact configuration while maintaining their individual optical accessibility from multiple faces during the replication process.
2Stability of the object's composition
If master elements are fixed in position, then structural stability is improved, but flexibility for exchanging and reconfiguring holograms is reduced
Solution Approach 1:
The carrier means incorporates adjustable and interchangeable master elements that can be dynamically reconfigured. Master elements can be exchanged, added, or removed based on replication requirements while maintaining stable positioning during the actual replication process through alignment features and securing mechanisms.
Solution Approach 2:
The carrier means is designed as a universal platform that can accommodate different types, sizes, and configurations of master elements. This multi-functional carrier system allows the same infrastructure to support various replication scenarios by simply changing the master element arrangement.
3Device complexity
If only one face of master elements is exposed, then the setup is simpler, but the versatility for different hologram types is limited
Solution Approach 1:
The patent extends exposure from a single-face (2D) approach to multi-face (3D) exposure by positioning light sources and master elements to allow illumination from multiple directions. This enables the replication of both reflection and transmission holograms, as well as volume holograms, using the same carrier means infrastructure.
4Reliability
If heavy transparent materials like glass are used for substrate bodies, then durability and optical quality are improved, but handling and exchanging become difficult
Solution Approach 1:
By segmenting the master elements into smaller, lighter components with lower individual weight, the patent maintains optical quality while significantly improving handling ease. The segmented approach allows individual elements to be manipulated without the cumbersome weight of large monolithic glass substrates.
Solution Approach 2:
The patent employs lighter, potentially replaceable master element substrates that can be exchanged frequently without the need for heavy-duty handling equipment. These lighter substrates may be optimized for specific applications and replaced as needed, reducing the operational burden of handling.
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 method reduces production costs, minimizes material waste, and enhances flexibility by allowing precise exposure of different holograms with varying requirements, improving efficiency and quality in hologram replication.
Implementation Method 1
exposing the master elements in order to replicate the master holograms in the light-sensitive composite web
Implementation Method 2
HOES (Holographic Optical Elements) typically denote optical components in which holographic properties are used to attain a specific beam path of the light, such as e.g. transmission, reflection, diffraction, scattering and/or deflection
Implementation Method 3
Holograms are created by the interference of a reference beam with the light reflected off the surface of an object (object beams)
Data Source
AI summary
A method includes providing a multiplicity of masters, each of the masters having a substrate body and at least one master hologram, selecting a sequence of masters from the multiplicity of masters based on a plurality of holograms to be replicated and arranging the sequence of masters on a first carrier to align upper faces of the masters in a horizontal plane, detachably laminating a light-sensitive composite web on the aligned upper faces, exposing the masters to replicate the master holograms in the light-sensitive composite web, and detaching the exposed composite web from the masters. The masters are detachably incorporated in the first carrier such that a sequence and/or composition of the masters for replicating the plurality of holograms is variable. The masters are incorporated in the first carrier such that two or more faces of the masters are optically accessible for exposure.