Patent Description:
The coherence length of a laser is a measure the propagation length of the laser's beam over which coherence degrades significantly. For purposes of holographic recording, a laser beam is split along two paths and recombined to form an interference pattern in a holographic film. If the beam splitter divides the beam power equally, and the two optical path lengths after the beam splitter are exactly equal, fringes of <NUM> percent contrast will be formed at the holographic film. If the two path lengths are unequal by more than the coherence length, the interference fringe contrast degrades significantly. In the example of an F15E dual-beam holographic combiner, the path length difference between the two interfering beams changes by approximately +/- <NUM> throughout the hologram aperture relative to a midpoint. Furthermore, the midpoint does not appear at the exact center of the hologram aperture.

An efficient hologram over the full hologram aperture requires a high contrast holographic interference pattern across the full aperture. In the case of the F15E combiner, the full aperture is approximately <NUM> inches. Thus, a coherence length greater than <NUM> is needed, with a path length of the two beams equalized at a point near the "zero" contour of the relative path length map. Large-aperture holographic optical elements, particularly those generated by interfering two differently shaped beams to form interference fringe surfaces that are not conformal to the substrate on which they are recorded, have typically used Argon-ion gas (Ar) lasers. The F15E holographic head-up display (HUD) combiner is one such product.

The benefits of Ar lasers include high power and potentially very long coherence length, the latter being enabled by an internal Fabry-Pérot etalon that selects a single frequency from among the many otherwise available within the gain curve of the laser tube.

However, dual-beam holograms exposed using a laser of very long coherence length are susceptible to the recording of secondary holograms caused by the exposure beams reflecting from the external glass-air interfaces of the substrate and cover-plate that surround the photosensitive holographic film. Such secondary holograms can generate undesirable artifacts in the image of the HUD, including secondary "ghost" images of the collimated image source, and/or transmission gratings that generate distracting "rainbows" surrounding bright external light sources such as, say, bright landing strip lights against a dark, nighttime background.

The magnitude of these secondary holograms, and the brightness of the undesirable image artifacts that they produce, can be reduced by limiting the coherence length of the laser. Ideally, the coherence length would be limited to just that necessary to generate a sufficiently efficient primary hologram, but no longer. As such, the additional path length differences introduced in the round-trip of each beam between the holographic film and the exterior air/glass interface reflections back to the film will exceed the coherence length of the laser, and the resulting secondary interference patterns that they generate at the film will be of reduced contrast. The resulting secondary holograms are thereby less efficient, reducing the brightness of the display artifact.

The most significant secondary holograms are formed by reflections of each beam from the external glass/air interfaces. The intensity of these reflections is reduced with the aid of antireflection coatings, which in turn reduces the intensity and contrast of the secondary fringe patterns. Nevertheless, these secondary holograms can still generate distracting artifacts in a HUD image, particularly against a dark, nighttime background. Because these reflections undergo additional optical path length before returning to the holographic film (e.g., approximately <NUM> from the thinner substrate and <NUM> from the thicker exposure coverplate), the secondary hologram intensity/contrast may be reduced further by minimizing the coherence length to just that necessary to record the primary hologram.

While there is no known method of "setting" a particular coherence length on a laser, it has been discovered empirically that when the etalon of a typical large frame, high-power Argon ion laser is removed altogether, the resulting longitudinal mode structure yields a coherence length that enables an efficient primary hologram and significantly reduced (but not eliminated) secondary holograms.

Another prior art method of reducing secondary hologram fringe contrast in a dual-beam hologram is disclosed in <CIT> and <CIT>. According to these references, the second beam is formed by a stationary free-form mirror (dominantly toroidal), the space between the film and the mirror is filled with an index-matching fluid, and a separate coverplate between the first beam and the film is intentionally moved with respect to the film throughout the exposure by piezo-electric transducers.

In the above "dual-beam" examples, the coherence length required is on the order of tens of millimeters. Another class of holographic optical element is one in which the holographic fringes are "conformal," that is, the second beam is formed by a reflection of the first beam at the surface of the holographic film, either from a mirror index-matched to the film, or from the film/air interface. The fringe planes are formed by such a reflection "conform" to the film/reflector surface. In this case, the coherence length necessary to form an efficient primary hologram is only on the order of the holographic film depth, typically no more than tens of microns - three orders of magnitude less than the F15 HUD combiner example referred to above. These are sometimes referred to as "single beam" or "conformal" holograms. Effective coherence can be reduced to desired levels in a relatively simple manner via controlled motion of the film plate with respect to the single exposure beam, or with the introduction of a moving diffuser in the exposure beam. <CIT> teaches such a moving (e.g., rotating) ground glass method.

It is also known to reduce effective coherence length by tuning the wavelength of the laser, in particular a tunable dye laser. This is described in <CIT>. This method was not reduced to practice due to practical limitations on available wavelength and power of such lasers, and the mechanisms by which they are tuned.

In recent years, solid-state lasers have become available at primary holographic exposure wavelengths (<NUM> and <NUM>), and at power levels similar to Argon ion lasers (e.g., <NUM>-4W). There is great motivation to transition away from Argon-ion lasers to solid-state lasers. Argon-ion lasers are much more expensive to buy, operate, and maintain, and they are extremely inefficient, requiring kilowatts of electricity at 440V to generate a couple watts of light. Modern solid-state lasers are compact and highly efficient, running off a standard wall outlet.

Since most of the Argon ion laser's electrical power is wasted as heat, the Argon ion laser requires a continuous and substantial flow of cooling water, more than can be provided with a practical recirculating chiller. The waste heat load on the equivalent solid-state laser is orders of magnitude smaller, compatible with either a small recirculating chiller or a heat sink fan. The mechanical vibration imparted to the holographic exposure table by the high flow rate of cooling water to the Argon ion laser presents a challenge to achieving the holographic fringe stability required of the entire exposure system, even with active fringe stabilization techniques. This can impact product yield. The solid-state laser introduces much less mechanical noise to the exposure table, especially when used with a small recirculating chiller instead of a fan.

Finally, Argon ion lasers have a more limited life. The laser tubes need frequent replacement, and the 440V power supplies need frequent repair. The equivalent solid-state laser has an expected lifetime much longer than that of an Argon ion laser tube, and costs less than a single laser tube replacement.

<CIT> discloses an apparatus comprising a laser and a heat generating unit operable to generate heat to regulate the temperature of the semiconductor laser element. This is controlled to maintain a constant fringe spacing between interference fringes having a plurality of interference fringes. The spacing is a measure of the wavelength of the laser. <CIT> makes use of the phenomenon that the temperature of a solid-state laser resonator correlates with the wavelength.

Modern, solid-state lasers are inherently single-frequency, long-coherence-length devices, but there is no known system or method to reduce coherence for large-aperture holographic exposures. Unlike Argon ion lasers, solid-state devices have no etalon that can be removed to limit the coherence without fundamentally changing the existing large and expensive exposure hardware infrastructure. As such, there is an outstanding need for a system and method to reduce, adjust and control the effective coherence length of a single-frequency, solid-state laser in a holographic optical element exposure.

Certain aspects of the present disclosure are directed to a system and methods for controlling and limiting the effective coherence length of a single-frequency, solid-state laser to reduce or eliminate spurious, secondary holograms in conjunction with a holographic optical element exposure.

The invention is set out in the set of claims. A method of exposing a holographic recording medium is set out in claim <NUM>, and a corresponding system is set out in claim <NUM>.

To accomplish this, the wavelength of the laser is varied or "scanned" over a very small wavelength range, thereby reducing the effective coherence length of the laser to a desired value. The wavelength of the laser is controlled with high precision over a very small wavelength range. The temperature of the laser's resonant cavity optical bench is altered during the exposure, causing the dimension of the cavity to change and thus changing the emission wavelength of the laser in a controlled manner. The changing emission wavelength is monitored at high resolution, and a feedback control loop updates the temperature set-point of the laser's resonant cavity optical bench to keep the monitored laser wavelength moving at a desired rate of change through a desired range.

As the wavelength of the laser is scanned during a holographic exposure, the phase of the holographic interference pattern is locked at a desired position of maximum coherence/contrast within the holographic film aperture. To facilitate this, an interferometer samples the two holographic exposure beams outside of the primary hologram aperture and deviates them along a common path to form an interference pattern. A detector monitors characteristics of the interference pattern and, as the laser wavelength is scanned, the detector signals are used in a feedback loop to drive piezoelectric transducers that add or subtract path length in one of the two exposure beams as necessary to keep the interference pattern phase locked at all wavelengths.

The path length difference between the two interfering beams is set to match the path length difference at the point in the primary hologram film aperture at which maximum fringe contrast is desired. This keeps the holographic fringe pattern also phase-locked at that same path-length-difference point, corresponding to the midpoint of the desired path-length difference content of the primary hologram being recorded, throughout the entire laser wavelength scan. The adjustable coherence length and position in space of the phase lock provide two degrees of freedom to optimize the trade-off between primary hologram performance and minimum secondary/spurious holograms.

The nominal emission wavelength of the laser is varied in accordance with a wavelength-time profile. This profile may be linear, stepped or curved/sinusoidal to produce similar effective coherence length control as integrated throughout the total exposure time. The number of cycles through the wavelength range may be arbitrary, as the objective is to spend a similar amount of exposure time at several wavelengths spread throughout the desired range. The present disclosure is ideally suited to large-aperture recordings such as those associated with head-up displays.

The method of exposing a holographic recording medium is set out in claim <NUM>.

In certain embodiments, the method may further comprise monitoring the nominal emission wavelength using an interferometer; and updating the temperature set-point in accordance with the wavelength-time profile via a feedback control loop.

In certain embodiments, varying the nominal emission wavelength of the laser in accordance with a wavelength-time profile may include varying the nominal emission wavelength at a predetermined rate of change throughout the exposure period. In certain embodiments, varying the nominal emission wavelength of the laser in accordance with a wavelength-time profile may include varying the nominal emission wavelength continuously throughout the exposure period.

The method may include sampling the first and second exposure beams at or near the recording medium to determine if the phase-lock of the fringe pattern is kept. The method may further include adjusting a path length of one of the first and second exposure beams in accordance with the determined phase to maximize the contrast of the fringe pattern.

In certain embodiments of the method, the nominal emission wavelength may varied over a spectral bandwidth of <NUM> picometers or less. The spectral bandwidth may be also in the range of about <NUM> to <NUM> picometers.

In certain embodiments of the method, the nominal emission wavelength may be controlled to within <NUM> picometers or less. The wavelength may be also controlled to within <NUM> picometer.

In certain embodiments of the method, the step of maintaining the phase of the first interference fringe pattern at a position of maximum coherence or contrast may include sampling the first and second exposure beams at or near the recording medium to determine the position of maximum coherence or contrast; and adjusting a path length of one of the first and second exposure beams to maintain the phase of the first interference fringe pattern at the position of maximum coherence or contrast as the nominal emission wavelength is varied.

The method may include deviating the first and second exposure beams along a common path from the recording medium to form a second interference fringe pattern; and detecting a peak, a null, or an edge of a fringe in the second interference fringe pattern.

In some embodiments of the method, the recording medium may define an aperture of <NUM> square inches or more. The recording medium may form a head-up display.

According to another aspect of the present disclosure, a system for exposing a holographic recording medium is set out in claim <NUM>.

In certain embodiments of the system, the wavelength monitor may be an interferometer. The apparatus for maintaining the phase of the first interference fringe pattern at a position of maximum coherence or contrast may include a device for deviating the two exposure beams along a common path from the recording medium to form a second interference pattern; a device for detecting a peak, null, or edge of a fringe in the second interference pattern; and a device for adjusting the path length of one of the first and second exposure beams to maintain the phase of the first interference fringe pattern at the position of maximum coherence or contrast. The device for deviating the first and second exposure beams along a common path from the recording medium may include a conformal beam splitter coating on the recording medium. The device for deviating the first and second exposure beams along a common path from the recording medium may include a second beam splitter component. The device for detecting a peak, null, or edge of a fringe in the second interference pattern may be an interferometer. The device for adjusting the path length of one of the first and second exposure beams to maintain the phase of the first interference fringe pattern include a piezoelectric transducer inserted into one of the first and second exposure beams.

In certain embodiments of the system, the apparatus for varying the nominal emission wavelength may be operative to vary a spectral bandwidth of the laser by <NUM> picometers or less. The apparatus for varying the nominal emission wavelength may operative to vary a spectral bandwidth of the laser in a range of about <NUM> to <NUM> picometers. The apparatus for varying the nominal emission wavelength may be operative to control the nominal emission wavelength to within <NUM> picometers or less. The apparatus for varying the nominal emission wavelength may operative to control the nominal emission wavelength to within <NUM> picometer.

In certain embodiments of the system, the recording medium defines an aperture of <NUM> square inches or more. The recording medium may form a head-up display.

According to another aspect of the present disclosure, a two-beam holographic recording system using a solid-state laser outputting a nominal emission wavelength, includes an improvement comprising controlling a temperature set-point of the laser to vary the nominal emission wavelength, thereby reducing an effective coherence length of the laser, while simultaneously maximizing a contrast of a recorded interference pattern.

The described embodiments and other features, advantages and disclosures contained herein, and the manner of attaining them, will become apparent and the present disclosure will be better understood by reference to the following description of various embodiments of the present disclosure taken in junction with the accompanying drawings, wherein:.

In accordance with the present disclosure, the wavelength of a single-longitudinal-mode (SLM) solid-state laser is varied or 'scanned' over a very small wavelength range, thereby reducing the effective coherence length of the laser to a desired value, as integrated over an extended time period, for purposes of reducing or eliminating spurious/secondary holograms in a holographic exposure. In scanning the wavelength of the laser during a holographic exposure, which scan may be several minutes long, the effective coherence length of the exposure is related to the wavelength content of the exposure by the following relationship: <MAT> Where:.

<NUM>, the coherence length is defined as the propagation length after which the magnitude of the coherence function has dropped to the value of <NUM>/e for a Lorentzian bandwidth distribution. As such, the coherence length is an approximation relative to what one might expect from a linear time-scanned laser wavelength at constant intensity. But as a good first approximation, EQN. <NUM> indicates that, for example, a coherence length of <NUM> at a nominal <NUM> wavelength would be generated by a wavelength scan of approximately <NUM> (or <NUM> picometers). An optimum balance between efficient primary and inefficient secondary holograms for the F15E exposure, for example, will fall somewhere in this order of magnitude. It was discovered experimentally that a good balance occurs at an actual wavelength scan width of approximately <NUM> picometers.

<FIG> is a schematic diagram illustrating a system <NUM> for holographic exposure and controls according to the present disclosure. In an embodiment according to the present disclosure, the system <NUM> may include a laser <NUM> having a laser emission wavelength. The laser <NUM> may be a single-longitudinal-mode solid-state laser such as an optically pumped semiconductor laser. In accordance with the present disclosure, the emission wavelength of the laser is controlled with high precision (e.g., on the order of <NUM> picometer) over a very small desired wavelength range (e.g., on the order of <NUM>-<NUM> picometers). The system reduces the effective coherence length of the laser to a desired value, as integrated over an extended time period, for purposes of reducing or eliminating spurious/secondary holograms in a holographic exposure.

The emission wavelength may be moved by adjusting a critical wavelength-sensitive laser cavity component of the laser <NUM>. In at least one embodiment, a temperature set-point of the resonant cavity optical bench <NUM> within the laser <NUM> is varied in increments on the order of <NUM>. The system <NUM> may control the temperature set-point of the resonant cavity optical bench <NUM> within the laser <NUM> by accessing control parameters of the laser <NUM>. Varying the temperature of the resonant cavity optical bench <NUM> in the laser <NUM> causes the dimension of the cavity to change and the emission wavelength to move accordingly in a continuous manner.

The emission wavelength is monitored at high resolution, for example, with a scanning interferometer <NUM>. In certain embodiments, the interferometer <NUM> may be a Fabry-Perot interferometer. A feedback control loop may be used to update a temperature set-point maintained by the laser <NUM> of the resonant cavity optical bench <NUM> to keep the monitored emission wavelength moving at a desired rate of change through the desired wavelength range. In certain embodiments, the feedback control loop may reverse the temperature change direction to keep the emission wavelength alternating between the boundaries of the desired wavelength range with a desired profile. <FIG>, discussed further herein, illustrates exemplary wavelength-time profiles.

As the wavelength of the laser <NUM> is scanned during a holographic exposure, a technique is used to keep the phase of the holographic interference pattern locked at the desired position of maximum coherence/contrast within a holographic film aperture <NUM>. To facilitate keeping the holographic interference pattern locked at the desired position, an additional interferometer <NUM> may sample holographic exposure beam <NUM> and holographic exposure beam <NUM> outside of the primary hologram aperture <NUM>, and deviate them along a common path to form an interference pattern at the interferometer <NUM>. Detectors in the interferometer <NUM> may monitor a peak and a null in this interference pattern. Note that interferometer <NUM> may be a generic phase-sensing system, typically detecting one or more of a peak, null, or edge of a fringe in the interferometer fringe pattern formed by beam splitter <NUM> combining exposure beams <NUM> and <NUM>. This fringe pattern may take the nominal form of linear, concentric (e.g., "bull's-eye"), elliptical or saddle/hyperbolic fringes, depending on the relative wavefront shapes of beams <NUM> and <NUM> and their degree of parallelism after beam splitter <NUM>. Note, further, that in practice beam splitter <NUM> may be a separate physical component, or a conformal beam splitter coating on the hologram exposure plate (as shown in <FIG>).

A piezo-electric transducer <NUM> may change the path length of exposure beam <NUM> as necessary in order to keep the fringe pattern phase locked (stationary) as the laser emission wavelength changes. The prism and/or optical shim <NUM> may be implemented in different ways, as separate devices, or as a single component. The prism function of the prism and/or optical shim <NUM> may deviate one beam angle (via the prism angle of the prism and/or optical shim <NUM>), as necessary, to be nominally parallel to the other beam after beams <NUM> and <NUM> are combined by beam splitter <NUM>.

The optical shim function of the prism and/or optical shim <NUM> may add optical path length (via the thickness of the prism and/or optical shim <NUM>) to one of the beams, as necessary, such that the path length difference of beam <NUM> and beam <NUM>, as measured between beam splitter <NUM> and beam splitter <NUM>, is identical to that at the desired position of maximum fringe contrast within the hologram active area, which may or may not be near the physical center. The shim function is therefore more critical, as the prism is a steering optic. Note, further, that the optical path tuning accomplished by the optical shim of the prism and/or optical shim <NUM>, and/or the beam deviation accomplished by the prism of the prism and/or optical shim <NUM>, may be implemented with reflective optics, for example, by adding a jog-out-and-back path on one beam to correct its path length, or a combination jog-and-angle-change using a series of mirrors to accomplish the same function(s).

As the laser wavelength is scanned, the detector signals from the interferometer <NUM> may be used in a feedback loop to drive the piezoelectric transducer <NUM> to add or subtract path length in one of the two exposure beams as necessary to keep the interference pattern phase locked at all wavelengths.

The path length difference between the two interfering beams may be set to match the path length difference at the point in the primary hologram film aperture <NUM> at which maximum fringe contrast is desired. This keeps the holographic fringe pattern also phase-locked at the same path-length-difference point, corresponding to the midpoint of the desired path-length difference content of the primary hologram being recorded, throughout the entire laser wavelength scan.

The adjustable coherence length and position in space of the phase lock provide two degrees of freedom to optimize the tradeoff between primary hologram performance and minimum secondary/spurious holograms.

<FIG> includes a graph <NUM> illustrating four wavelength-time profiles according to the present disclosure. The graph <NUM> shows four possible profiles through the total exposure time T. λ<NUM> is the nominal wavelength of the laser exposure, and Δλ is the spectral wavelength bandwidth. Though <FIG> illustrates ramp and sawtooth profiles, the wavelength-time profiles need not be linear. Other possible wavelength-time profiles include stepped or curved/sinusoidal to produce similar effective coherence length as integrated throughout the total exposure time. The number of cycles through the wavelength range is also arbitrary, as the objective is to spend a similar amount of exposure time at several wavelengths spread throughout the desired range.

While the present disclosure has been described with respect to reflection holograms, the same coherence and secondary holograms formed by glass-air reflections, and the solutions described herein, apply equally well to transmission holograms, including those used in Raman and astronomical spectroscopic gratings (wherein the recording beams arrive from the same side of the film).

Further, while the beam-forming optics accommodate the recording of a curved plate, flat and other recording element geometries are anticipated. While the present disclosure is well suited to large-aperture holograms of the type suited to head-up displays, informational combiners, large-format scientific and astronomical gratings having apertures of <NUM> square inches and more, the present disclosure is not limited in terms of hologram size. Nor is the present disclosure limited in terms of holographic recording media, which may include dichromated gelatin, photo emulsions and resists, polymers, thermoplastics and refractives.

Claim 1:
A method of exposing a holographic recording medium, comprising the steps of:
providing a solid-state laser (<NUM>) configured to output a laser beam having a nominal emission wavelength;
splitting the laser beam into first and second exposure beams to form a path length difference and a first interference fringe pattern in the recording medium during an exposure period;
varying the nominal emission wavelength of the laser (<NUM>) in accordance with a wavelength-time profile to reduce an effective coherence length of the laser (<NUM>) as integrated over the exposure period, wherein the nominal emission wavelength of the laser (<NUM>) is varied by adjusting a temperature set-point of a resonant cavity optical bench (<NUM>) of the laser (<NUM>);
setting the path length difference between the first and second exposure beam to match a path-length-difference point in the holographic recording medium with maximum fringe contrast and keeping the fringe pattern phase-locked at that path-length-difference point; and
maintaining the first interference fringe pattern phase-locked at a position of maximum contrast while the holographic recording medium is being exposed throughout the entire emission wavelength variation.