Multi-layer Diffraction Grating Lens Additive Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing diffraction gratings are complex and limited, requiring sophisticated equipment and specific approaches, which hinder the development of easy-to-manufacture and repeatable diffraction gratings with concise output.
Innovation Solution
A novel additive manufacturing method involving the 3D printing of multi-layer lenses with alternating layers of curable materials, where each layer is cured to specific levels, forming a 3D rectangular-like shape that diffracts light effectively, allowing for the creation of diffraction gratings with controlled thickness and optical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional methods are used to manufacture diffraction gratings, then the diffraction grating can be produced, but the manufacturing process becomes complex and requires sophisticated equipment
Solution Approach 1:
The patent replaces traditional mechanical manufacturing methods with additive manufacturing (3D printing). The curable material layer is deposited and cured layer by layer to form the diffraction grating structure, eliminating the need for complex mechanical processing equipment and traditional manufacturing steps.
Solution Approach 2:
The patent utilizes the curing parameter of the curable material to control the formation of each layer. By controlling the curing level (CA for first layer, CB for second layer) during the 3D printing process, the diffraction grating structure is precisely formed without requiring complex mechanical operations.
2Reliability
If traditional manufacturing methods are used, then diffraction gratings can be produced, but the manufacturing approach is limited and not repeatable
Solution Approach 1:
The patent divides the diffraction grating into multiple layers with different curing levels. The first curable material layer is cured to a first predetermined curing level, and the second curable material layer is cured to a second predetermined curing level. This segmentation allows for precise control and repetition of the manufacturing process.
Solution Approach 2:
By controlling the curing parameters (CA and CB) of different material layers during the 3D printing process, the patent achieves repeatable and consistent diffraction grating production. The parameter control ensures that each layer is formed with the desired properties, enabling reliable reproduction of the diffraction grating structure.
3Manufacturing precision
If existing manufacturing methods are used, then diffraction gratings can be made, but the equipment required is sophisticated and costly
Solution Approach 1:
The patent replaces sophisticated mechanical equipment with additive manufacturing technology. The 3D printing process deposits and cures material layers to form the diffraction grating, achieving precise diffraction output without requiring complex mechanical processing equipment.
Solution Approach 2:
The patent uses composite curable materials with different curing levels (first curable material with curing level CA, second curable material with curing level CB) to create the diffraction grating structure. This allows for precise control of the grating properties and consistent diffraction output through material composition rather than complex equipment.
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 enables the easy and repeatable production of diffraction gratings that provide consistent and precise diffraction output, suitable for applications such as angular movement sensing systems, without the need for complex equipment, and can be adapted for various shapes and materials.
Implementation Method 1
Diffraction gratings are generally implemented to spatially disperse light. In particular, a diffraction grating can be used to spatially disperse a wide-spectrum light into light of different wavelengths.
Implementation Method 2
depositing a layer of a curable material to a height of ZLi, curing the layer of step (a) to a predetermined curing level CA
Data Source
AI summary
A multi-layer lens is disclosed which includes a plurality of dual-layer structures staked on top of one-another, wherein each dual-layer Ri of the plurality of dual-layers includes i) a first curable material having a height of ZLi cured at a predetermined curing level CA, and ii) a second curable material having a height of Zgi cured at a predetermined curing level CB.