Roll Printed Dispersive Optical Elements with Microscale Features
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Solution Overview
Problem
Traditional subtractive manufacturing techniques for diffraction gratings lead to defects, contamination, and high costs due to complex processing steps, which are not effectively addressed by automated variations of these methods.
Innovation Solution
The use of additive manufacturing methods, specifically roll printing to form materials with microscale features, which are then adhered to substrates with optical coatings, offering a lower cost and lower temperature process that minimizes defects and contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional subtractive manufacturing techniques (masking and etching) are used to form diffraction gratings, then the grating structure can be created on the substrate, but defects and contamination occur due to complex processing steps
Solution Approach 1:
The patent inverts the traditional subtractive manufacturing approach by using additive manufacturing. Instead of building material and removing it through masking and etching, the invention directly forms the grating structure by depositing material in the desired pattern, eliminating the harmful masking and etching steps that cause defects and contamination.
Solution Approach 2:
The patent extracts and removes the harmful processing steps (masking and etching) from the manufacturing process. By eliminating these intermediate steps, the invention directly creates the grating structure through deposition alone, thereby removing the source of defects and contamination associated with traditional subtractive methods.
2Manufacturing precision
If traditional subtractive manufacturing processes are used, then diffraction grating structures can be formed, but processing costs become high due to complex processing steps
Solution Approach 1:
The patent inverts the traditional manufacturing sequence by using additive rather than subtractive processes. This inversion simplifies the manufacturing process by eliminating multiple complex steps (masking, etching, cleaning), thereby reducing processing costs while maintaining grating structure formation capability.
Solution Approach 2:
The patent discards the traditional subtractive manufacturing workflow entirely in favor of an additive approach. By abandoning the complex sequence of masking and etching operations, the invention recovers processing efficiency and reduces costs associated with these unnecessary intermediate steps.
3Productivity
If automated variations of subtractive manufacturing methods are used, then production efficiency may improve, but defects and contamination are not effectively addressed
Solution Approach 1:
The patent inverts the manufacturing approach from automated subtractive methods to additive manufacturing. This fundamental inversion eliminates the source of defects and contamination by removing the masking and etching steps, while simultaneously maintaining high production efficiency through direct material deposition processes.
Solution Approach 2:
The patent extracts the harmful elements (masking and etching steps) from the automated manufacturing process. By eliminating these problematic intermediate steps, the invention achieves both high productivity through streamlined processing and freedom from defects and contamination that plague traditional automated subtractive methods.
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 creation of dispersive optical elements with varied microscale features, suitable for diverse applications, including monochromators and spectrometers, while maintaining the integrity of optical coatings and reducing processing costs.
Implementation Method 1
forming a film including microscale features by a roll printing process
Implementation Method 2
The material is then adhered to either an uncoated or coated substrate
Data Source
AI summary
A dispersive optical element includes a substrate including a dielectric material, an optical coating arranged on the substrate, and a layer of material including a microscale feature arranged directly on the optical coating.