High Refractive Index Optical Layer Diffracting Structures
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Solution Overview
Problem
Existing methods for manufacturing optical elements are limited by the refractive index of the glue layer, restricting the diffraction angle and optical performance.
Innovation Solution
Forming diffracting optical structures on an optical layer made from a high refractive index material, using a carrier with a bonding layer and mold layer to create microstructures, and then applying an optical layer with a high refractive index to enhance diffraction angles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a glue layer is used to form diffracting optical structures, then the manufacturing process is simple, but the diffraction angle is limited by the refractive index of the glue layer
Solution Approach 1:
The patent changes the refractive index parameter from using glue layer material (limited refractive index) to using a mold layer material with higher refractive index. This parameter change enables achieving larger diffraction angles while maintaining the imprinting manufacturing method.
Solution Approach 2:
The patent introduces a mold layer as an intermediary component between the substrate and the final optical element. The mold layer with high refractive index serves as the medium for forming diffracting structures, overcoming the limitation of glue layer's low refractive index.
2Temperature
If a high refractive index material is used for the optical layer, then the diffraction angle is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent performs preliminary action by forming the diffracting optical structures on the mold layer before removing the mold layer. This allows the high refractive index structures to be created first, then transferred to the final optical element, simplifying the overall process.
Solution Approach 2:
The patent uses the mold layer as a template or copy that is later removed. The diffracting structures are formed on this temporary mold layer and then transferred to the final optical element, avoiding the need to directly work with high refractive index materials in the final assembly step.
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
The method enables the production of optical elements with higher diffraction angles, improving optical performance.
Implementation Method 1
a mold layer is formed on the bonding layer. The mold layer has a first surface and a second surface, which are opposite to each other. The first surface is adjacent to the bonding layer. The second surface is set with microstructures
Implementation Method 2
various diffracting optical structures are formed on an optical layer, which is made from a high refractive index material, such that the optical element with a higher diffraction angle is obtained
Data Source
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AI summary
An optical element and a method for manufacturing the optical element are described. The optical element includes a light penetrating substrate, an optical layer, and an adhesive layer. The optical layer is located on a surface of the light penetrating substrate. The optical layer has a first surface and a second surface, which are opposite to each other. The first surface is set with various diffracting optical structures. A refractive index of the optical layer is ranging from 1 to 4. The adhesive layer is sandwiched between the surface of the light penetrating substrate and the second surface of the optical layer.