PATENT DOCUMENT

Publication Number: US-11422292-B1
Application Number: US-201916428999-A
Country: US
Kind Code: B1

Title: Super-blazed diffractive optical elements with sub-wavelength structures

Abstract:
An optical element includes first and second transmission gratings positioned in mutual proximity and in a mutually-parallel orientation and having respective first and second phase modulation profiles with a common period and different, respective first and second numbers of modulation peaks and troughs in each period.

Claims:
The invention claimed is: 
     
       1. An optical element, comprising:
 a first transmission grating having a first phase modulation profile comprising a first pattern of alternating peaks and troughs, which repeats itself for each shift of one predefined period in the grating direction and comprises a given number of first peaks, having a first width, in each period; and 
 a second transmission grating positioned in proximity and in a parallel orientation to the first transmission grating and having a second phase modulation profile comprising a second pattern of alternating peaks and troughs, which repeats itself for each shift of the same period as the first pattern along the same grating direction and comprises the same given number of second peaks, having a second width, and also comprises third peaks, interleaved between the second peaks and having a third width different from the second width, in each period. 
 
     
     
       2. The optical element of  claim 1 , wherein a distance between neighboring peaks of the first and second transmission gratings in a direction perpendicular to a common plane of the gratings does not exceed 0.5 μm. 
     
     
       3. The optical element of  claim 1 , wherein the peaks of the first and second transmission gratings are offset in the grating direction by a distance selected so as to maximize a diffraction efficiency of the optical element into a given diffraction order at a given wavelength and polarization of light. 
     
     
       4. The optical element of  claim 1 , wherein the given number is one. 
     
     
       5. The optical element of  claim 1 , wherein the given number exceeds one. 
     
     
       6. The optical element of  claim 1 , wherein the first and second transmission gratings comprise surface-relief micro-structures, which define the first and second phase modulation profiles. 
     
     
       7. The optical element of  claim 6 , wherein the first and second transmission gratings comprise respective first and second substrates having respective surfaces on which the surface-relief micro-structures are formed, and wherein the first and second substrates are arranged so that the respective surfaces on which the surface-relief micro-structures are formed are mutually-adjacent. 
     
     
       8. The optical element of  claim 7 , wherein the first and second substrates are arranged so that the peaks in the surface-relief micro-structures of the first and second transmission gratings are separated by a distance no greater than 500 nm. 
     
     
       9. A method for producing an optical element, comprising:
 providing a first transmission grating having a first phase modulation profile comprising a first pattern of alternating peaks and troughs, which repeats itself for each shift of one predefined period in the grating direction and comprises a given number of first peaks, having a first width, in each period; 
 providing a second transmission grating having a second phase modulation profile comprising a second pattern of alternating peaks and troughs, which repeats itself for each shift of the same period as the first pattern along the same grating direction and comprises the same given number of second peaks, having a second width, and also comprises third peaks, interleaved between the second peaks and having a third width different from the second width, in each period; and 
 positioning the second transmission grating in proximity and in a parallel orientation to the first transmission grating. 
 
     
     
       10. The method of  claim 9 , wherein positioning the second transmission grating comprises mounting the first and second transmission gratings so that a distance between neighboring peaks of the first and second transmission gratings in a direction perpendicular to a common plane of the gratings does not exceed 0.5 μm. 
     
     
       11. The method of  claim 9 , wherein positioning the second transmission grating comprises mounting the first and second transmission gratings so that the peaks of the first and second transmission gratings are offset in the grating direction by a distance selected so as to maximize a diffraction efficiency of the method into a given diffraction order at a given wavelength and polarization of light. 
     
     
       12. The method of  claim 9 , wherein the given number is one. 
     
     
       13. The method of  claim 9 , wherein the given number exceeds one. 
     
     
       14. The method of  claim 9 , wherein the first and second transmission gratings comprise surface-relief micro-structures, which define the first and second phase modulation profiles. 
     
     
       15. The method of  claim 14 , wherein the first and second transmission gratings comprise respective first and second substrates having respective surfaces on which the surface-relief micro-structures are formed, and wherein positioning the first and second transmission gratings comprises mounting the first and second transmission gratings so that the respective surfaces on which the surface-relief micro-structures are formed are mutually-adjacent. 
     
     
       16. The method of  claim 15 , wherein the first and second substrates are mounted so that the peaks in the surface-relief micro-structures of the first and second transmission gratings are separated by a distance no greater than 500 nm.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Patent Application 62/682,944, filed Jun. 10, 2018. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to optical elements, and particularly to diffractive optical elements. 
     BACKGROUND 
     Diffractive optical elements (DOEs) are a group of optical elements that use diffractive structures, such as gratings, to modulate the local phase of incident light. Such elements can be designed to operate in a reflective mode or in a transmissive mode. DOEs possess unique optical properties that often cannot be attained with optical elements operating on refractive or reflective principles. 
     Surface-relief DOEs, comprising surface-relief micro-structures, are an important subset of DOEs. The spatial dimensions of these micro-structures vary from a fraction of the operating wavelength to several hundred wavelengths. The period of the phase modulation profile of a DOE, measured in a direction parallel to the surface of the DOE, controls the angles of diffraction between the incident light and the diffracted orders. The profile of the micro-structure, defined by the height and shape characteristics of the peaks and troughs in the micro-structure, controls the diffraction efficiencies into the various orders. For example, for a DOE with a period significantly larger than the operating wavelength, most of the propagating light can be directed at a very high diffraction efficiency into a single diffraction order when the profile of the micro-structure satisfies the so-called blazing condition (see Y. Soskind,  Field Guide to Diffractive Optics , pp. 56-59, SPIE Press, Bellingham, Wash., 2011). 
     SUMMARY 
     Embodiments of the present invention that are described hereinbelow provide improved DOEs and methods for their manufacture and use. 
     There is therefore provided, in accordance with an embodiment of the invention, an optical element, including first and second transmission gratings positioned in mutual proximity and in a mutually-parallel orientation and having respective first and second phase modulation profiles with a common period and different, respective first and second numbers of modulation peaks and troughs in each period. 
     In a disclosed embodiment, a distance between neighboring modulation peaks of the first and second transmission gratings in a direction perpendicular to a common plane of the gratings does not exceed 0.5 μm. Additionally or alternatively, the modulation peaks of the first and second transmission gratings are offset in a direction perpendicular to the common plane by a distance selected so as to maximize a diffraction efficiency of the optical element into a given diffraction order at a given wavelength and polarization of light. 
     In one embodiment, the first number is one and the second number is two. In an alternative embodiment, the first number exceeds one and the second number exceeds the first number. 
     In some embodiments, the first and second transmission gratings include surface-relief micro-structures, which define the first and second phase modulation profiles. Typically, the first and second transmission gratings include respective first and second substrates having respective surfaces on which the surface-relief micro-structures are formed, and the first and second substrates are arranged so that the respective surfaces on which the surface-relief micro-structures are formed are mutually-adjacent. In a disclosed embodiment, the first and second substrates are arranged so that the modulation peaks in the surface-relief micro-structures of the first and second transmission gratings are separated by a distance no greater than 500 nm. 
     There is also provided, in accordance with an embodiment of the invention, a method for producing an optical element, which includes providing first and second transmission gratings having respective first and second phase modulation profiles with a common period and different, respective first and second numbers of modulation peaks and troughs in each period. The first and second transmission gratings are positioned in mutual proximity and in a mutually-parallel orientation. 
     The present invention will be more fully understood from the following detailed description of the embodiments thereof, taken together with the drawings in which: 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic cross-section of a composite DOE, in accordance with an embodiment of the invention; and 
         FIGS. 2 and 3  are schematic sectional views of DOEs incorporated in a composite DOE, in accordance with an embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
     The diffraction efficiencies of surface-relief DOEs can be controlled by the appropriate design of the profile of the micro-structure of the surface relief. For example, a blazed transmissive DOE with a period of 20 μm and a saw-tooth shaped profile with a height of 2.08 μm, operating at a wavelength of 0.94 μm, exhibits very high diffraction efficiencies to the first (+1) diffraction order at 2.69°: The DOE will diffract 92.7% of incident TE-polarized light and 92.2% of incident TM-polarized light into the +1 order, with concomitant low diffraction efficiencies to other orders. (The terms “optical radiation” and “light” as used in the present description and in the claims refer generally to any and all of visible, infrared, and ultraviolet radiation.) The diffraction efficiency of a DOE into a given diffraction order is defined as the ratio between the optical power diffracted into that order and the optical power of the light impinging on the DOE. 
     On the other hand, reducing the period to 2.0 μm to increase the +1 order diffraction angle to 28.0° requires a blazed profile height of 1.62 μm, and will result in +1 order diffraction efficiencies of only 49.1% for TE-polarized light and 48.4% for TM-polarized light. By increasing the blazed profile height, higher diffraction efficiencies can be achieved, but at the cost of increasing fabrication difficulties. 
     In some designs, each period of the surface relief can be further divided into sub-wavelength structures, with the advantage that higher diffraction efficiencies that can be achieved at relatively shallow profile heights, using relatively simple binary step profiles. Although the profiles in such designs are shallower than those of blazed gratings, the division of the profile into sub-wavelength sections again leads to high aspect ratios with associated challenges for accurate fabrication. 
     Embodiments of the present invention that are described herein address these problems by providing an optical element, which is a composite of two DOEs comprising transmission gratings positioned in mutual proximity. The gratings have phase modulation profiles with a common period, but each grating has a different number of modulation peaks and troughs in each period. 
     In the embodiments described hereinbelow, the transmission gratings comprise surface-relief micro-structures, which define the first and second phase modulation profiles. Although the two DOEs of the composite DOE have low aspect ratios, thus enabling accurate fabrication, the diffraction efficiencies of the composite DOE are very high (&gt;80%) even for high diffraction angles. Alternatively, the principles of the present invention may be applied, mutatis mutandis, to DOEs having other types of phase modulation structures. 
     In the disclosed embodiments, the two DOEs are produced individually, using methods that are known in the art, and are then positioned and mounted parallel to and facing each other, meaning that the substrates on which the surface-relief micro-structures are formed are arranged so that the micro-structures on the two substrates are mutually-adjacent, and their peaks and troughs mutually parallel. The modulation peaks in the surface-relief micro-structures on one DOE are typically separated from the modulation peaks on the other DOE by a fraction of the operating wavelength, for example by 500 nm or less. The lateral shift between the respective microstructures on two DOEs (meaning the offset between the modulation peaks in the two transmission gratings), as well as the separation between the DOEs, is chosen so as to maximize the diffraction efficiency of the composite DOE into a given diffraction order at a given wavelength and polarization of light. 
     In an embodiment of the present invention, one DOE includes one peak and one trough in each period of its phase modulation profile, whereas the other DOE includes two or more pairs of peaks and troughs in each period. In the design of the composite DOE, the duty cycles of the pairs of peaks and troughs in each DOE are determined so as to maximize the diffraction efficiency of the composite DOE for the given diffraction order, wavelength and polarization. 
     Additionally or alternatively, both the phase modulation profiles and the relative positions (separation and offset) of the two DOEs are designed so as to simultaneously both maximize the diffraction efficiency and minimize the reflection losses of the composite DOE. 
       FIG. 1  is a schematic cross-section of a composite DOE  10 , in accordance with an embodiment of the invention. Composite DOE  10  includes a first DOE  12  and a second DOE  14 , with respective front surfaces  17  and  19  and respective surface-relief micro-structures formed on the front surfaces. Referring to Cartesian coordinates  11 , the height profile of the micro-structures on each front surface  17  and  19  is defined as the height of each point on the surface in the z-direction from, respectively, a back plane  13  of first DOE  12  and a back plane  15  of second DOE  14 , wherein the back planes lie parallel to the xy-plane. 
     The height profile can be seen as a phase modulation profile, as it modulates the phase of the optical waves impinging on the surface. The phase modulation profile comprises successive peaks and troughs, where peaks refer to points of the front surface that are farthest from the respective back plane, and troughs refer to points of the front surface that are closest to the respective back plane. The phase modulation profiles of both front surfaces  17  and  19  are periodic in the x-direction with a common period d, but with a constant profile in the y-direction. Thus, the phase modulation profile repeats itself for each shift of one period d in the x-direction. A grating vector  21 , common to the first and second DOEs  12  and  14 , respectively, is defined as a vector in the x-direction (in the plane of the DOEs and perpendicular to the peaks and troughs) with a length of 1/d in units of inverse length. 
     One period of first DOE  12  includes a first peak  16  and a first trough  18 . One period of second DOE  14  includes a second peak  20  and a third peak  22  interleaved with a second trough  24  and a third trough  26 . Details of the widths of peaks  16 ,  20 , and  22  and of troughs  18 ,  24 , and  26 , are shown in  FIGS. 2-3 . 
     In an example embodiment, the period common to first DOE  12  and second DOE  14  is d=2.0 μm; the distance between the bottoms of the troughs of the two DOEs is h=2.0 μm; and the heights of the peaks of the two DOEs are h 1 =h 2 =0.95 μm, meaning that the peaks on one DOE are separated from those on the other DOE by only 100 nm. The lateral offset between the respective micro-structures on the first DOE  12  and second DOE  14 , measured from a left edge from first peak  16  to a left edge of third peak  22 , is t=0.17 μm. 
       FIG. 2  is a schematic cross-section of first DOE  12  of  FIG. 1 , in accordance with an embodiment of the invention. The width of first peak  16  is wp 1 =0.675 μm, and the width of first trough  18  is wt 1 =1.325 μm. A first duty cycle ds 1  is defined as wp 1 /wt 1 ; in the present embodiment ds 1 =0.509. 
       FIG. 3  is a schematic cross-section of second DOE  14  of  FIG. 1 , in accordance with an embodiment of the invention. The width of second peak  20  is wp 2 =0.4 μm, the width of third peak  22  is wp 3 =0.6 μm, and the widths of second and third troughs  24  and  26 , respectively, are wt 2 =0.5 μm and wt 3 =0.5 μm. 
     For the embodiment disclosed in  FIGS. 1-3 , the calculated diffraction efficiency of composite DOE  10  for TM-polarized light with a wavelength of 0.94 μm for the +1 order at a diffraction angle of 28.0° is 94.5%, and the calculated reflection losses are 1%. The dimensions of composite DOE  10  may be optimized for TE-polarized light at the same wavelength, leading to a calculated diffraction efficiency of 93.9% and reflection losses of 2.5%. The high diffraction efficiencies, as well as low reflection losses, of the disclosed embodiment are achieved by iteratively optimizing the duty cycles ds 1 , ds 2 , and ds 3 , the heights h 1  and h 2 , the separation h, and the lateral offset t, using a physical model of the interaction of the incident light with the phase modulation profile. 
     Due to a coherent interaction of light between first DOE  12  and second DOE  14 , the diffraction efficiency of composite DOE  10  in the present embodiment is much higher than that of each of the two DOEs separately. Similarly, the reflection losses of composite DOE  10  are much lower than the reflection losses of either first DOE  12  or second DOE  14 . 
     In alternative embodiments, the numbers of peaks and troughs in the two DOEs forming a composite DOE may be chosen from other combinations of unequal numbers, such as, for example, one peak/trough-pair in the first DOE and three peak/trough-pairs in the second DOE, or two peak/trough-pairs in the first DOE and three peak/trough-pairs in the second DOE, or any other combination of unequal numbers for the peak/trough-pairs in the two DOEs. For each combination of peak/trough-pairs, the dimensions of the two DOEs are optimized similarly to the optimization of the embodiment disclosed in  FIGS. 1-3 . 
     It will be appreciated that the embodiments described above are cited by way of example, and that the present invention is not limited to what has been particularly shown and described hereinabove. Rather, the scope of the present invention includes both combinations and subcombinations of the various features described hereinabove, as well as variations and modifications thereof which would occur to persons skilled in the art upon reading the foregoing description and which are not disclosed in the prior art.

Metadata:
Filing Date: 20190602
Publication Date: 20220823
Grant Date: 20220823
Priority Date: 20180610
Inventors: SOSKIND, YAKOV G.
Assignee: APPLE INC
CPC Classifications: [{"code": "G02B5/1847", "inventive": false, "first": false, "tree": "[]"}, {"code": "G02B5/1823", "inventive": true, "first": true, "tree": "[]"}, {"code": "G02B5/1809", "inventive": false, "first": false, "tree": "[]"}, {"code": "G02B5/1823", "inventive": true, "first": true, "tree": "[]"}, {"code": "G02B5/1847", "inventive": true, "first": false, "tree": "[]"}, {"code": "G02B5/1847", "inventive": true, "first": false, "tree": "[]"}, {"code": "G02B5/1823", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 82930046