Patterned Dichroic Filter with Blanket Anti-Reflective Coating
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Solution Overview
Problem
Existing methods for producing dichroic filters struggle to achieve thin filters with well-defined edges and complete spectral characteristics, often requiring multiple filters and complex manufacturing processes.
Innovation Solution
The integration of microlithography and optical arts to deposit dichroic filter material using a 'cold process' on a substrate, followed by the application of a blanket coating to complete spectral characteristics, allowing for patterned dichroic filters with sharply defined edges and reduced complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple layers of dichroic materials are deposited to achieve complete spectral characteristics, then the spectral performance is improved, but the manufacturing complexity and device thickness increase
Solution Approach 1:
The patent divides the filter into two functional segments: patterned dichroic layers for wavelength-selective reflection and a blanket anti-reflective coating for spectral completion. This segmentation allows each layer to be optimized independently, reducing overall manufacturing complexity while maintaining spectral performance.
Solution Approach 2:
The patent merges the dichroic filter layers with a blanket anti-reflective coating in a single manufacturing process sequence. The anti-reflective coating is applied over the patterned dichroic layers, combining multiple functions (wavelength selection and reflection optimization) into a unified structure that simplifies fabrication.
2Manufacturing precision
If multiple dichroic layers are used to achieve precise spectral characteristics, then the spectral precision is improved, but the filter thickness and device complexity increase
Solution Approach 1:
The patent applies different properties to different regions: the patterned dichroic layers provide wavelength-selective reflection in specific regions, while the blanket anti-reflective coating provides optimized spectral characteristics across the entire surface. This local differentiation achieves precise spectral control without uniformly increasing thickness throughout the entire filter.
3Ease of manufacture
If traditional dichroic filter manufacturing is used, then the filter can be produced, but the edges are not sharply defined and multiple filters are required
Solution Approach 1:
The patent replaces traditional mechanical stacking of multiple separate filters with a layer-based deposition process. The patterned dichroic layers are deposited directly onto the substrate using vapor deposition techniques, and the anti-reflective coating is applied as a continuous blanket layer, eliminating the need for mechanical assembly of multiple discrete filter components and achieving sharp edges through precise layer definition.
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 enables the production of dichroic filters with enhanced optical properties and simplified manufacturing, eliminating the need for multiple filters and achieving precise spectral performance.
Implementation Method 1
The art of microlithography has long been employed to produce microelectronic devices
Implementation Method 2
a 'cold process,' well known in the art of microelectronics, is employed to deposit the filter material
Implementation Method 3
The spectral characteristics are completed by adding a blanket coating of a material such as an anti-reflective material
Implementation Method 4
Dichroic filters, also known as interference filters, are constructed by depositing one or more layers of metallic and/or dielectric films with precise thicknesses to produce filters which transmit certain wavelengths of light and reflect others
Data Source
AI summary
A combination patterned reflective dichroic filter and optical coating, and method of making the same, is disclosed by starting with a filter substrate, laying down a pattern of dichroic filter material, but stopping short of completing the layers required for the spectral characteristics of the filter. The spectral characteristics are completed by adding a blanket coating of a material such as an anti-reflective material. In an alternative embodiment the blanket coating can be applied prior to addition of the dichroic filter material.