Multilayer Optical Structure Fabrication via Temporary Erasure
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Solution Overview
Problem
The fabrication of multilayer optical devices, such as holographic waveguide devices, faces challenges in planarity, contamination, and increased processing time and costs due to the stacking and alignment of waveguides, which can lead to beam deflection and optical inefficiencies.
Innovation Solution
A method involving the temporary erasure of optical structures in a first layer to allow recording of a second optical structure using optical exposure processes with light beams traversing the first layer, enabling the formation of multilayer waveguide stacks with overlapping layers, separated by substrates or encapsulated in cells, and implemented in a roll-to-roll fabrication process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If waveguides are stacked and aligned to form multilayer optical devices, then multiple optical functions can be integrated, but planarity is compromised and beam deflection occurs
Solution Approach 1:
The patent combines multiple optical structures into a single integrated waveguide layer rather than stacking separate waveguides. The method records multiple optical functions (input coupling, output coupling, beam steering) within the same layer, eliminating the need for physical stacking and alignment of multiple waveguide layers, thus maintaining planarity while achieving multiple optical functions.
Solution Approach 2:
The patent transitions from a three-dimensional stacking approach (multiple layers stacked vertically) to a two-dimensional integration approach (multiple functions within a single layer). By recording different optical functions at different positions within the same waveguide layer, the invention eliminates the vertical dimension of stacking, thereby maintaining planarity and avoiding beam deflection associated with misaligned layers.
2Adaptability or versatility
If multiple waveguide layers are stacked, then multiple optical functions can be achieved, but alignment difficulties increase processing time and costs
Solution Approach 1:
The patent merges multiple optical functions into a single waveguide layer, eliminating the need for multiple separate fabrication and alignment steps. All optical functions are recorded in one continuous process within the same layer, dramatically reducing processing time and eliminating the costly alignment procedures required for stacked waveguides.
Solution Approach 2:
The patent performs preliminary planning of all optical functions within the single layer before fabrication begins. The waveguide structure is designed to accommodate multiple functions (input coupling, output coupling, beam steering) at predetermined positions, allowing all functions to be recorded in one step without subsequent alignment operations.
3Adaptability or versatility
If waveguides are stacked to achieve multiple optical functions, then functional versatility increases, but optical inefficiencies arise due to beam deflection
Solution Approach 1:
The patent combines multiple optical functions within a single planar waveguide layer, ensuring that all optical paths are contained within the same refractive index structure. This eliminates beam deflection at layer interfaces and maintains consistent optical efficiency across all functions (input coupling, output coupling, beam steering) while preserving functional versatility.
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 provides optically efficient and cost-effective fabrication of multilayer optical devices by allowing light to pass through temporarily erased structures, reducing beam deflection and enhancing processing efficiency, while maintaining optical performance.
Implementation Method 1
During the recording process, the monomers polymerize and the mixture undergoes a photopolymerization-induced phase separation
Implementation Method 2
Holographic optical elements, such as volume phase gratings, can be recorded in such a liquid mixture by illuminating the material with two mutually coherent laser beams
Implementation Method 3
temporarily erasing the first optical structure by applying an external stimulus... the external stimulus includes a stimulus selected from the group that includes: an optical stimulus, a thermal stimulus, a chemical stimulus, a mechanical stimulus, an electrical stimulus, and a magnetic stimulus
Implementation Method 4
applying an optical exposure process to the second layer to form a second optical structure, wherein the optical exposure process includes using at least one light beam traversing the first layer
Implementation Method 5
planar waveguides can be designed to utilize diffraction gratings to diffract and couple incident light into the waveguide structure such that the in-coupled light can proceed to travel within the planar structure via total internal reflection
Implementation Method 6
planar waveguides can be designed to utilize diffraction gratings to diffract and couple incident light into the waveguide structure
Data Source
AI summary
Systems and methods for fabricating optical elements in accordance with various embodiments of the invention are illustrated. One embodiment includes a method for fabricating an optical element, the method including providing a first optical substrate, depositing a first layer of a first optical recording material onto the first optical substrate, applying an optical exposure process to the first layer to form a first optical structure, temporarily erasing the first optical structure, depositing a second layer of a second optical recording material, and applying an optical exposure process to the second layer to form a second optical structure, wherein the optical exposure process includes using at least one light beam traversing the first layer.