Segmented Optical Elements for Large-Scale Retroreflection
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Solution Overview
Problem
Conventional methods for manufacturing retroreflective optical elements face challenges in achieving high accuracy and large size due to material limitations, particularly when using flexible materials, leading to degraded image quality and limited maximum size.
Innovation Solution
The method involves forming optical element units with regular triangular or hexagonal shapes, arranging them on a substrate to mimic molecular structures like graphene or carbon nanotubes, and processing the substrate into desired surface shapes, allowing for high-accuracy, large-scale production using glass or resin materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If retroreflective optical elements are made using conventional molding methods with flexible materials, then production cost is reduced and adaptability is improved, but manufacturing precision deteriorates and image quality degrades
Solution Approach 1:
The optical element is divided into multiple small optical elements (e.g., 1000 pieces of 3mm diameter) that are arranged in a specific pattern on a substrate. Each small element can be manufactured with high precision using conventional molding methods, while the segmented structure allows the overall element to achieve large size and complex shapes that would be difficult to mold as a single piece.
Solution Approach 2:
Multiple small optical elements are nested or arranged on a substrate to form a larger optical element. This nested structure enables the combination of high-precision small elements with large overall dimensions and flexible configurations, resolving the contradiction between manufacturing precision and ease of manufacture for large-scale elements.
2Length of stationary object
If the size of the optical element is increased using conventional molding, then the maximum size is limited to about 30 cm due to molding difficulties, but if flexible materials are used to exceed this size, then manufacturing precision deteriorates
Solution Approach 1:
The large optical element is segmented into multiple small optical elements that can each be molded with high precision using conventional methods. By arranging these small elements on a substrate, the overall size can exceed 30 cm without compromising the precision of individual elements, as each small element remains within the optimal molding size range.
Solution Approach 2:
The patent transitions from molding a single large three-dimensional optical element to arranging multiple small two-dimensional or simple three-dimensional elements on a substrate plane. This dimensional approach allows large overall size while maintaining precision, as the complexity is distributed across multiple simple units rather than concentrated in one large unit.
3Manufacturing precision
If stacking of glass or nanoimprinting is used to achieve high accuracy retroreflection, then manufacturing precision is improved, but device complexity and production cost increase
Solution Approach 1:
Instead of using complex stacking of glass plates or nanoimprinting processes for the entire optical element, the patent segments the element into multiple small units that can be manufactured using simpler conventional molding methods. This segmentation reduces the complexity of the manufacturing process while maintaining retroreflection accuracy through the collective arrangement of precision-small elements.
Solution Approach 2:
The patent employs multiple small optical elements that can be manufactured using cost-effective conventional molding methods rather than expensive glass stacking or nanoimprinting. While individual elements are simple, their collective arrangement achieves the required precision, making the overall system more cost-effective and manufacturable.
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 high-quality, large-sized optical elements with improved accuracy and flexibility, enabling cost-effective mass production while maintaining image quality, suitable for aerial image displays and spatial input devices.
Implementation Method 1
The retroreflective member 40 reflects light L3 in the same direction as incident light
Data Source
AI summary
A method for manufacturing an optical element includes forming an optical element unit comprised of an optical material such as glass and having an outer shape of a regular triangle or a regular hexagon, arranging a plurality of optical element units two-dimensionally on a substrate so as to have a structure imitating a molecular structure of graphene or a carbon nanotube, and processing the substrate on which the plurality of optical element units are mounted into a desired surface shape.