# US 2016/0259232 A1 · Method and apparatus for making a high resolution light pattern generator on a transparent substrate

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- Number: US 2016/0259232 A1
- Document ID: US20160259232A1
- Status: Published application
- Kind: A1
- Application number: 15/065,555
- Filed: 2016-03-09
- Published: 2016-09-08
- Earliest claimed: 2008-06-30
- Assignees: Production Resource Group, LLC
- Applicants: Production Resource Group, LLC
- Inventors: Thomas Hough; James Bornhorst
- Web page: https://patentgrep.com/patent/US20160259232A1

## CPC

- G03B 21/14: Details
- F21V 11/00: Screens not covered by groups F21V1/00, F21V3/00, F21V7/00 or F21V9/00 (characterised by cooling arrangements F21V29/502)
- G03F 7/2053: {using a laser (ablative removal B41C)}
- F21W 2131/406: for theatres, stages or film studios
- G03B: APPARATUS OR ARRANGEMENTS FOR TAKING PHOTOGRAPHS OR FOR PROJECTING OR VIEWING THEM; APPARATUS OR ARRANGEMENTS EMPLOYING ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ACCESSORIES THEREFOR (optical parts of such apparatus G02B; photosensitive materials or processes for photographic purposes G03C; apparatus for processing exposed photographic materials G03D)
- F21V: FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
- G03F: PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR; (phototypographic composing devices B41B; photosensitive materials or processes for photographic purposes G03C; electrophotography, sensitive layers or processes therefor G03G)
- F21W: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO USES OR APPLICATIONS OF LIGHTING DEVICES OR SYSTEMS

## Abstract

A light pattern generator that can be used to form a gobo for use in a projection optical system. A transparent plate is coated with a stack that is absorptive and reflective. The stack is formed to be ablatable in the form of a pattern. The stack can have multiple different layers with multiple different characteristics, all of which are ablated by the laser.

## Claims

### Claim 1

A method comprising: forming an optical structure comprising a transparent plate with front and rear sides, and having a coating stack bonded to one of said sides of the transparent plate, said coating stack comprising: a release layer that is an ultraviolet absorber that is vaporized by application of ultraviolet radiation, a dark coating which absorbs ultraviolet; and a reflector layer, coupled to said dark coating;
Processing said optical structure by using a UV laser that passes through said transparent plate to said coating stack, to vaporize said release layer and ablate a portion of said dark coating adjacent to a location of vaporizing said release layer.

### Claim 2 (depends on 1)

A method as in claim 1, further comprising producing a light beam through said optical structure after said processing, to shape said light beam.

### Claim 3 (depends on 1)

A method as in claim 1, wherein said reflector layer has multiple layers of reflector material.

### Claim 4 (depends on 1)

The method as in claim 1, wherein said processing forms a shape in said coating stack which changes a shape of said light beam.

### Claim 5 (depends on 1)

A method as in claim 1, wherein said forming further comprising using an anti-reflection coating on the front side of the transparent plate, said coating being substantially transmissive to radiation.

### Claim 6 (depends on 5)

A method as in claim 5, wherein said coating stack is on said rear side of said transparent plate.

### Claim 7 (depends on 1)

A method as in claim 1, wherein said coating stack is on said front side of said transparent plate.

### Claim 8

A method comprising:
directing a UV laser through an optical structure formed of a transparent plate with front and rear sides and which has a coating stack bonded to the rear side of the transparent plate, said coating stack comprising:
a first layer which is vaporized by UV radiation;
a second layer substantially absorptive to radiation in a second range; and
a third layer substantially reflective to radiation in a third range; and
using said UV laser to vaporize areas of said first layer and ablate portions of said second layer and third layer which are adjacent to said areas of said first layer.

### Claim 9 (depends on 8)

A method as in claim 8, wherein said second range and said third range are the same.

### Claim 10 (depends on 8)

A method as in claim 8, further comprising producing a light beam through said optical structure after said using, to shape said light beam.

### Claim 11 (depends on 10)

A method as in claim 10, wherein said directing forms a shape in said coating stack which changes a shape of said light beam.

### Claim 12 (depends on 8)

A method as in claim 8, further comprising using an anti-reflection coating on the front side of the transparent plate, said coating being substantially transmissive to radiation.