Multi-Section Mirror Focusing for Off-Axis Optical Sensors

Solution Overview

Problem

Existing photonic inspection systems face challenges in efficiently collecting off-axis light, leading to degraded signal-to-noise ratio and increased costs due to the need for high-power light sources and complex refractive optics.

Innovation Solution

Deployment of a multi-section mirror-based optics system that efficiently collects and channels off-axis light to photodetectors, eliminating the need for high-power light sources and expensive refractive optics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If conventional refractive optics are used to collect off-axis light, then light collection efficiency is improved, but device complexity and cost increase

Engineering Contradiction:

Improvelight collection efficiencyVSAvoidoptics system complexity

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The mirror is divided into multiple sections, each independently positioned and angled to collect light from different off-axis angles. This segmentation allows the system to handle complex light collection requirements through simpler, modular components rather than a single complex refractive optic.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent transitions from refractive optics (volume-based light manipulation) to reflective optics (surface-based light manipulation). By using mirrors positioned at different spatial locations and angles, the system collects off-axis light through spatial arrangement rather than through complex lens geometries, reducing overall device complexity.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Illumination intensity

If high-power light sources are used to compensate for poor light collection, then signal intensity is improved, but energy consumption and cost increase

Engineering Contradiction:

Improvesignal intensityVSAvoidenergy consumption

Core Design Contradiction:

Illumination intensityVSUse of energy by moving object

Solution Approach 1:

The patent converts the previously harmful off-axis light (which was not being collected efficiently) into a beneficial resource. By positioning multiple mirror sections to specifically capture off-axis light and redirect it to the photodetector, the system turns wasted light into useful signal, improving signal intensity without increasing light source power.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Ease of manufacture

If conventional single-mirror designs are used, then manufacturing simplicity is maintained, but light collection efficiency deteriorates

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidlight collection efficiency

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

The mirror is divided into multiple sections, each independently positioned and angled to collect light from different off-axis angles. This segmentation allows the system to handle complex light collection requirements through simpler, modular components rather than a single complex refractive optic.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Each mirror section is independently positioned and angled to optimize light collection from specific directions. This local optimization allows each section to be relatively simple in design while the collective arrangement achieves superior overall light collection efficiency.

Inventive Principle:

Principle #3Local quality

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

Improves signal-to-noise ratio by concentrating light at the center of photodetectors, reducing costs and potential failure points, and minimizing dispersion artifacts.

Implementation Method 1

a first section of the multi-section mirror can include a first parabolic reflector that collects off-axis light incident on the first section and reflects the collected off-axis light onto a first portion of the photodetector

Methodology Applied

Scientific EffectReflection: Reflection

Implementation Method 2

a first section of the multi-section mirror can include a first parabolic reflector that collects off-axis light incident on the first section and reflects the collected off-axis light onto a first portion of the photodetector

Methodology Applied

Scientific EffectFocusing: Focusing

Data Source

PatentUS20250305944A1Optimized mirror-based light focusing for optical sensor assembly

Publication Date: 2025.10.02 APPLIED MATERIALS INC

AI summary

Disclosed systems include a mirror having multiple optical sections positioned about an axis of the mirror. Each optical section includes an opening leading to a respective section of a light sensor and configured to collect a portion of an incident beam of light. The focal distance of the mirror is optimized and set based on a size of the opening, a size of the illuminated area of the light sensor, a distance from the mirror to the light sensor, and/or the like.