Optical Component Structure Positioning for Phase Distortion Control
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Solution Overview
Problem
Traditional manufacturing techniques for electronic and optical components often introduce unwanted distortions, such as edge diffraction and wavefront distortion, due to variations in structure height, leading to suboptimal performance and user frustration.
Innovation Solution
A modified production master or working stamp is configured to position structures at a specific bias distance from a planar surface, minimizing distortions by optimizing the offset height of optical elements, and adjusting the mould to ensure uniform offset distances for optical elements on a substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional imprinting and molding techniques are used to manufacture optical components, then manufacturing process is simple, but unwanted distortions including edge diffraction and wavefront distortion occur
Solution Approach 1:
The patent applies preliminary action by pre-compensating for expected manufacturing variations in the master mold design. The master mold incorporates predetermined offset adjustments that anticipate and correct for variations that will occur during the imprinting process, thereby reducing edge diffraction and wavefront distortion before the actual manufacturing takes place
Solution Approach 2:
The patent implements parameter changes by systematically varying the offset distance of structures from the planar surface based on their position. The offset amount is adjusted as a parameter to compensate for manufacturing variations, with different offset values applied to different regions of the optical component to minimize distortions
2Ease of manufacture
If structures are positioned with variations in height from the planar surface, then manufacturing is easier, but phase distortions and edge diffraction increase
Solution Approach 1:
The patent applies local quality by positioning structures at different offset distances from the planar surface depending on their specific location. Rather than using a uniform height for all structures, the offset distance is locally adjusted for each structure or region to compensate for manufacturing variations and minimize phase distortions and edge diffraction at each specific location
Solution Approach 2:
The patent implements feedback by measuring the actual offset distance of structures from the planar surface and using this information to adjust the master mold positioning. The system compares measured offset distances with target values and applies corrective positioning adjustments to minimize phase distortions and edge diffraction in subsequent manufacturing cycles
Data Source
AI summary
Techniques for generating electronics components that operate free of unwanted distortions such as edge diffraction and unwanted phase jumps are described. A modified production master or a modified working stamp can be implemented to generate an electronic or optical component having structures that are positioned within a desired distance from a planar surface. A production master or a working stamp is modified in dependence upon a comparison of an identified distance for each respective structure to the planar surface and a desired distance. The modified production master or the modified working stamp generates the electronic or optical component by positioning the structures in accordance with the desired distance. By positioning the structures in accordance with the desired distance, electronic components generated using the modified production master or the modified working stamp minimize distortions, such as a phase jump between the structures.