Metasurface with overcoat and equal pillar spacing

Patent metadata

Field	Value
Publication number	US-12455401-B2
Application number	US-202318112152-A
Country	US
Kind code	B2
Filing date	Feb 21, 2023
Priority date	Apr 19, 2022
Publication date	Oct 28, 2025
Grant date	Oct 28, 2025

Abstract

Optical metasurfaces can manipulate a light wavefront without traditional lenses. They can include pillars with subwavelength dimensions on a substrate. The pillars can vary in size, shape, and spacing across a surface of the substrate. Each pillar size and shape can diffract incident light and provide a unique electromagnetic response. The metasurface can provide desired light wavefront manipulation without the thickness of traditional lenses. The metasurface can overcome the aberration problem of traditional lenses. An overcoat layer can be located at a distal-end of the pillars. Pillar pitch can be adjusted for uniform spacing between pillars, and uniform overcoat coverage. The overcoat layer can protect the pillars. An alternative to the overcoat layer is a solid fill-material filling gaps between the pillars.

First claim

What is claimed is:

1 . A metasurface optical device comprising:
an array of pillars on a substrate, including different pillars with different diameters with respect to each other; each pillar has a proximal-end nearest the substrate and a distal-end farthest from the substrate; D 5 /D 1 ≥2, where D 5 is a diameter of a largest diameter pillar and D 1 is a diameter of a smallest diameter pillar, both diameters D 5 and D 1 measured halfway between the proximal-end and the distal-end; G 1 /G 5 ≤1.5, where G 1 is a gap between the smallest diameter pillar and a nearest adjacent pillar of the array, and G 5 is a gap between the largest diameter pillar and a nearest adjacent pillar of the array, both gaps G 1 and G 5 measured halfway between the proximal-end and the distal-end; P 55 /P 11 ≥1.5, where P 55 is a pitch between two of the largest pillars and P 11 is a pitch between two of the smallest pillars, proximate to each other; and an overcoat layer located at the distal-end of the pillars, the overcoat layer spanning gaps between the pillars.

2 . The device of claim 1 , wherein D 5 /D 1 ≥3 and G 1 /G 5 ≤1.2.

3 . The device of claim 1 , wherein a pitch between adjacent, smaller pillars is less than a pitch between adjacent, larger pillars.

4 . The device of claim 1 , wherein a pitch between proximate pillars throughout the array is not uniform.

5 . The device of claim 1 , wherein the overcoat extends down sidewalls of the pillars for a distance of ≥5% and ≤90% from the distal-end towards the proximal-end.

6 . The device of claim 1 , wherein the overcoat extends down sidewalls of the pillars, and variation of a distance of the overcoat extending down the sidewalls across the device is +/−10% from an average distance.

7 . The device of claim 1 , wherein the proximal-end of the pillars are located in a proximal-plane and the distal-end of the pillars are located in a distal-plane.

8 . The device of claim 1 , wherein the overcoat extends down sidewalls of the pillars for a distance of ≤90% from the distal-end towards the proximal-end.

9 . The device of claim 1 , wherein:
the pillars have a uniform thickness; the thickness is measured perpendicular to the substrate; and the thickness is ≥100 nm and ≤2 μm.

10 . A metasurface optical device comprising:
an array of pillars on a substrate, including different pillars with different diameters with respect to each other; each pillar has a proximal-end nearest the substrate and a distal-end farthest from the substrate; D 5 /D 1 ≥2, where D 5 is a diameter of a largest diameter pillar and D 1 is a diameter of a smallest diameter pillar, both diameters D 5 and D 1 measured halfway between the proximal-end and the distal-end; a pitch between the smallest diameter pillar and a nearest adjacent pillar of the array is less than a pitch between the largest diameter pillar and a nearest adjacent pillar of the array; and gaps between proximate pillars are uniform; and an overcoat layer located at the distal-end of the pillars, the overcoat layer spanning gaps between the pillars.

11 . The device of claim 10 , wherein the overcoat extends down sidewalls of the pillars, and variation of a distance of the overcoat extending down the sidewalls across the device is +/−10% from an average distance.

12 . The device of claim 10 , wherein the different pillars with different diameters include at least five different pillars with different diameters with respect to each other.

13 . The device of claim 10 , wherein the pillars are transparent across the visible light spectrum.

14 . The device of claim 10 , wherein:
each pillar has a thickness measured perpendicular to the substrate that is ≥100 nm and ≤2 μm; each pillar has a diameter that is ≥25 nm and ≤750 nm; a pitch of adjacent pillars is ≥75 nm and ≤2 μm; and the overcoat has a thickness measured perpendicular to the substrate that is ≥50 nm and ≤750 nm.

15 . The device of claim 10 , wherein the gaps are air-filled.

16 . The device of claim 10 , wherein the pillars have a uniform thickness.

17 . The device of claim 10 , wherein D 5 /D 1 ≥3.

18 . The device of claim 10 , wherein the overcoat extends down sidewalls of the pillars for a distance of ≥5% and ≤90% from the distal-end towards the proximal-end.

19 . The device of claim 10 , wherein the overcoat extends down sidewalls of the pillars for a distance of ≤90% from the distal-end towards the proximal-end.

20 . The device of claim 10 , wherein the proximal-end of the pillars are located in a proximal-plane and the distal-end of the pillars are located in a distal-plane.

Assignees

• Moxtek Inc

Inventors

• Bacon-Brown Daniel
• Williams Bradley R

Classifications

• G02B5/1809

  with pitch less than or comparable to the wavelength · CPC title

• G02B1/002 Primary

  made of materials engineered to provide properties not available in nature, e.g. metamaterials · CPC title