US 20050174646 A1
A diffuser is disclosed which transmits or reflects incident light into a specific range of angles. In a preferred embodiment, this light is uniformly scattered throughout a cone of angles. The diffuser consists of two parts. The first part diffracts or reflects light into a specific offset angle. The second part, in the preferred embodiment, uniformly scatters the light through a range of angles, which is centered on the offset angle. The diffusers have utility in applications such as screens for wrist watches, computers, calculators, and cell phones.
16. A method for making a directional reflector having a reflective surface, wherein the reflective surface includes at least one periodic surface comprising a plurality of periodic surface pieces and wherein the period surface pieces are each described by a parabolic function and reflect an incident ray throughout a specified uniform cone of angles, comprising the steps of:
creating a gray scale mask;
transmitting recording light through the gray scale mask such that a desired parabolic function is displayed; and
recording the desired parabolic function in a layer of photoresist.
17. The method for making a directional reflector having a reflective surface of
18. The method for making a directional reflector having a reflective surface of
21. A method for making a directional reflector for reflecting an amount of incident light, the directional reflector having a reflective surface, wherein the reflective surface has a periodicity on the order of a wavelength of the incident light and wherein the reflective surface further includes a coarse periodicity having an asymmetrical blazed profile and a fine periodicity, comprising the steps of:
creating the coarse periodicity having an asymmetrical blazed profile by prism coupling and recording into a layer of photoresist using more than one beam, wherein each beam is separated by a small angle and wherein each beam is incident at a large oblique angle; and
creating the fine periodicity by reflecting a single beam from the layer of photoresist using prism coupling.
22. The method for making a directional reflector having a reflective surface of
23. A method for obtaining white light using a directional reflector having a reflective surface, wherein the reflective surface has a periodicity on the order of a wavelength of incident light and wherein the reflective surface further includes a coarse periodicity having an asymmetrical blazed profile and a fine periodicity, comprising the steps of:
creating the coarse periodicity having an asymmetrical blazed profile by prism coupling and recording into a layer of photoresist using more than one beam, wherein each beam is separated by a small angle and wherein each beam is incident at a large oblique angle;
creating the fine periodicity by reflecting a single beam from the layer of photoresist using prism coupling; and
recording the fine periodicity in adjacent narrow parallel stripes, wherein each stripe reflects a different color.
24. A method for making a directional reflector having a reflective surface, the reflective surface comprising a first periodic surface component having a periodic wedge-shape, the periodic wedge-shape having a first period and a second periodic surface component, the second periodic surface component having a second period, wherein the combination of the first periodic surface component and the second periodic surface component cause an oblique light ray, which is incident on the reflective surface, to be reflected into a cone of rays, comprising the steps of:
mechanically ruling the wedge-shape;
creating a plastic replica from the mechanical ruling;
creating a random array of shallow parabolic depressions by spraying the plastic replica-with a fine droplet spray containing a plastic solvent.
25. The method for making a directional reflector having a reflective surface of
creating a metal replica from the sprayed plastic replica;
creating a second plastic replica from the metal replica; and
spraying the second plastic replica with a fine droplet spray containing a plastic solvent.
26. The method for making a directional reflector having a reflective surface of
This application is a divisional application of U.S. Ser. No. 10/639,552, filed Aug. 12, 2003, which is a divisional application of U.S. Ser. No. 09/920,060, filed Aug. 1, 2001 (now U.S. Pat. No. 6,608,722), which claims priority to U.S. Ser. No. 60/222,182, filed on Aug. 1, 2000, both of which are incorporated herein by reference.
The present invention relates generally to an optical diffuser and method for making the same, and more particularly to an optical diffuser having a high diffraction efficiency, broadband response and cost effective method of producing the same.
Reflective diffusers are required for many applications, including liquid crystal displays, to enhance their viewability. Often these diffusers, placed behind the liquid crystal element, are simply roughened reflective surfaces. These reflectors utilize no back lighting, but instead rely on the scattered reflection of the ambient light. Unfortunately, light scattered from these devices is centered around the glare angle, which is in direct line-of-sight with the undesirable reflections from their front surface. Furthermore in many applications, such as computer screens, and perhaps watches, the preferred orientation of the device is one for which viewing at the glare angle is not optimum. The situation can be improved by using holographic diffusers which allow the reflection angles of interest to be offset, so that the maximum brightness from the diffuser falls in a preferred viewing angle which is different from that of the glare. One type of holographic diffuser that is sometimes used is the reflective, “surface-relief” hologram. This hologram has the advantage over other types in that if the ambient light is white, the reflected diffuse light is also white. Another advantage of the surface-relief hologram is that embossing can reproduce it easily and inexpensively. A major disadvantage is that the surface-relief hologram can be inefficient. Only a relatively small percentage of the incident light is diffracted into the desired viewing angles (typically less than 30 degrees).
A non-holographic diffuser, when coupled with a reflective focusing screen, uses randomly sized and randomly placed minute granules, which are created by interaction of solvent particles on plastic surfaces (See U.S. Pat. No. 3,718,078, entitled, “Smoothly Granulated Optical Surface and Method for Making Same”). These granules are dimples of extremely small magnitude (one half of a micron in depth), which reflect incident light more or less uniformly over a restricted angle. However, the angles of reflectance are very small, usually about + or −3 degrees, and the light reflected from them is here again at the glare angle.
A second kind of off-axis, holographic diffuser in common use today is the volume reflection diffuser, which can be provided by Polaroid Corporation of Cambridge Mass. With volume holograms, fringes that give rise to the diffuser reflection are distributed throughout the volume of the material, unlike the surface reflection concept of the “surface-relief” holograms. Because of this, light of a wavelength that is characteristic of the spacing distance between the fringe planes is resonantly enhanced over all other wavelengths. Thus, the reflected light is highly monochromatic. For example, if the spacing is characteristic of green, then green will be the predominant reflected color for incident white light. Unlike conventional embossed holographic diffusers, the reflection can be extremely efficient, although only over a narrow wavelength band. As a result, the surface-relief hologram can appear dim because most of the incident white light falls outside of this select band. Further processing can increase the bandwidth, thus increasing the apparent brightness, but the resulting diffuser still has a predominant hue, which is in most cases undesirable. In any event the bandwidth is still somewhat restricted, thus limiting the reflection efficiency.
Therefore, an unsolved need has remained for a diffuser having a high diffraction efficiency, broadband response and cost effective manufacture, which overcomes limitations of the prior art.
In an embodiment of the present invention as set forth herein is a blazed diffuser, which includes a reflective surface having a sawtooth structure. The sawtooth structure includes a series of contiguous wedges, each of which reflects incident oblique light into a beam which is more or less normal to the gross surface of the device. This wedge structure may be regarded as simply an off-axis mirror if the wedge spacing (period) is much larger than the wavelength. Superimposed on this wedge surface is a second structural component, which by itself diffracts incident light normal to its surface into rays, which constitute only those over a restricted narrow angle (e.g. + or −15 degrees). This angle is specified as that which is desired for a particular application. In an embodiment, this second surface shape is one that uniformly scatters an incident ray throughout the viewing angle. Such a structure gives a so called “flat top” scattering. When these two structures are superimposed, light incident from a predetermined angle which is dependent on the wedge angle, is uniformly scattered throughout a specified range of viewing angles with a high degree of efficiency. Almost all incident light is utilized and efficiencies approaching 100% for all visible wavelengths are possible.
In another embodiment, a blazed diffuser is made entirely by optical, holographic means, and it can be fabricated in such a way that the broadband spectral colors are properly mixed so that the diffracted light appears white. The recording for this diffuser is done in two primary ways. The first is by recording directly from a predetermined diffuse surface, and the second is by copying from a volume diffuser into a surface diffuser.
The foregoing and other objects of this invention, the various features thereof, as well as the invention itself, may be more fully understood from the following description, when read together with the accompanying drawings in which:
The present invention provides an improved diffuser having a high diffraction efficiency, broadband response and method for making the same.
Referring further to
There are a variety of surface shapes that may be used for these structures. In the present embodiment, a shape for an element of the resulting combined surface can be described by the simple equation:
Simple microlens arrays may be approximated by periodic, two-dimensional parabolic surface arrays and as such have been used successfully to create flat top diffraction patterns, i.e., uniform on-axis reflection (or transmission) over a specific range of angles. Theoretically, a plane wave of incident light is uniformly reflected from a periodic surface throughout a specific range of angles because it has a constant second derivative.
In general, the diffraction from any reflective phase surface element, s(x), can include:
The integral in equation 3 is known as the Fresnel integral.
A typical plot of the amplitudes of the diffraction function of equation 3, is shown as the dashed curve 7 of
For parabolic structures, the diffraction function for elements 9 and 12, shown in
The function f′ is the complex conjugate of f (i.e., f′=f*), a result that is evident from Fourier analysis, and so the amplitude of f′ is also represented by the dashed curve 7 of
The structures 13 and 14 shown in
Because of the additional phase terms in equation 5, the dashed curve 10 of
The surface shown in
A surface which approximates the undulating parabolic surface of
Another method of producing a parabolic surface structure holographically is by the coherent interference of three laser beams in a layer of photoresist. If the sources of expanded light from each of the beams are arranged such that each source is approximately at the apex of an equilateral triangle, then the developed pattern in the photoresist will consist of a close-packed honeycomb array. By using suitable nonlinear etching characteristics of the photoresist, each honeycomb depression will develop in the shape of a paraboloid.
While the specific examples discussed so far relate to the reflection of incident light from a surface in air (i.e., n=1), the analysis also applies to cases in which the light is reflected from a surface that is covered, for example, by a plastic overcoating. In an embodiment, a reflective diffuser is provided, which includes a reflective surface that is embossed into the underside of a plastic sheet. In this embodiment, slight modifications to the analysis must be made, mainly in an alteration of the depth of the structure. (In equation 2, for example, s(x) becomes n s(x), where n is the index of refraction of the plastic). Also certain modifications would enable these devices to be used as transmission diffusers, rather than reflection diffusers.
Construction of surfaces discussed herein, and examples of which are shown in
The randomness may be achieved for example by using small portions of the prerequisite parabolic surface, which are randomly positioned but which on the aggregate cause reflected light to be more or less uniformly reflected over the desired angle.
Another process, described in the following, is a direct holographic method. The structure created by this method is different than that discussed so far, in that the period p is of the same order as the wavelength, λ, and thus diffraction effects become important.
The parameters of
One method of creating the periodic wedge is by recording the interference of two counterpropagating laser beams, 20 and 21 in
The preceding discussion represents the types of calculations that must be made in order to accurately form the fringe planes, and thus the sawtooth structure in a photoresist material, which is ultimately used as a master copy for mass production. In an embodiment, at least one of the beams, 20 and 21, in
If there were no diffuse component to the beam, then the light diffracted from the sawtooth surface relief structure would, for incident white light, display all the spectral colors from violet to red, although each would be viewable from a different angle. But controlled diffusion is a requirement of this technology. Adding a diffuse component to obtain white light means adding a variation in the grating period p or in the slope of the sawtooth, so that all colors are mixed at the same diffraction angle. For example, taking the extremes of 400 nm for violet and 700 nm for red, the period p for these two colors is, respectively, p=400/sin 30°=800 nm (violet) and p=700/sin 30°=1400 nm (red) for the same diffraction angle of 30 degrees. If these extremes in the period for the visible spectrum are now present as part of the surface relief structure, then the diffraction angles for the design wavelength of 500 nm range from 38.68 degrees to 20.92 degrees, so that the total variation is 8.68+9.08=17.76 degrees. Since the diffuser is nominally designed to operate at an angular spread of plus or minus 15 degrees from the main diffraction angle of 30 degrees (or a total angular spread of 30 degrees), there is sufficient angular variation for mixing the entire visible spectrum sufficiently to produce white light.
A method for making the diffuse structure is to use a split beam holographic setup and a predetermined diffuse surface. This method allows for flexibility in the range of recording angles. The method does, however, require the fabrication of a diffuse plate with the requisite viewing angles, which is inserted into at least one of the two recording beams. In one configuration, as shown in
Copying directly from a volume diffuser, as an alternative to the above, has many advantages. One advantage relates to a volume diffuser with the requisite offset and viewing angles, which can be efficiently produced holographically. Another advantage relates to the copying procedure, which is simpler than direct recording using a predetermined diffuse master, provided certain conditions are met. One of these conditions is that the peak wavelength of light diffracted from the master falls roughly into the center of the visible spectral range. Also the volume diffuser, which is used for copying, can have the proper angular spread to create an adequate viewing angle in the reflective mode.
A method of forming a structure like that of
In order to create beams 20 and 21 at angles of 49.56 degrees and 30.08 degrees (as shown in
Here again the angle for beam 20 in the photoresist is greater than the critical angle (49.56>36.03) and we must resort to coupling by means of a liquid gate. The photoresist plate is placed in a rectangular tank containing an index matching liquid for glass at n≈1.5 (e.g., xylene) that is liquid coupled to an equilateral prism, as shown in
Variations of the methods disclosed here can result in efficient directional diffusers. For example, with the first type disclosed, uniform angular spreading of the incident beam may be accomplished by a variation of either the period p or the slope θ/2 from sawtooth element to sawtooth element. However, such a procedure may require that the element size p be reduced (for example from 100 λ to 10 or 20 λ) so as to preserve the smooth visual texture of the diffuser. If the size p is too large, visible portions of the diffuser will not scatter into the observation direction.
A variation of the holographic method discussed herein, is the addition of a fine diffusing structure to a coarse wedge structure. This coarse wedge structure is of larger dimensions than that of the methods described in
A diffuse component can be added in a second exposure step by contacting the photoresist layer 33 to a reflective diffuser 39, as shown in
An alternate technique adds a fine step structure to the coarse wedge of
The diffraction efficiency for a ten-level structure is shown in
As can be seen from
Another variation on this method consists of first making a wedge grating structure of large periodicity and adding the step structure or diffuse structure to it holographically. In this configuration, it is similar to the structure shown in
The discussion has focused on devices that uniformly scatter light through a solid angle. But in some applications it may be desirable to achieve non-uniform scattering. One can modify the processes to create blazed diffusers that have a wide range of scattering properties.
Both categories of structures have been described in the foregoing in reference to their scattering properties in one dimension only. That is, the emphasis has been on showing how an incident beam whose obliquity to the surface (i.e., θ=30°) is scattered uniformly throughout an angle α, as in
Having thus described at least one illustrative embodiment of the invention, various alterations, modifications and improvements will readily occur to those skilled in the art. Such alterations, modifications and improvements are intended to be within the scope and spirit of the invention. Accordingly, the foregoing description is by way of example only and is not intended as limiting.