CN101389993B - 光学单元及其制造方法 - Google Patents

光学单元及其制造方法 Download PDF

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Publication number
CN101389993B
CN101389993B CN2005800431590A CN200580043159A CN101389993B CN 101389993 B CN101389993 B CN 101389993B CN 2005800431590 A CN2005800431590 A CN 2005800431590A CN 200580043159 A CN200580043159 A CN 200580043159A CN 101389993 B CN101389993 B CN 101389993B
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China
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mentioned
lens
support component
optics
optical unit
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CN101389993A (zh
Inventor
北村嘉朗
熊泽诚二
船见浩司
高田和政
西原泰生
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Panasonic Holdings Corp
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Matsushita Electric Industrial Co Ltd
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    • G—PHYSICS
    • G11—INFORMATION STORAGE
    • G11B—INFORMATION STORAGE BASED ON RELATIVE MOVEMENT BETWEEN RECORD CARRIER AND TRANSDUCER
    • G11B7/00—Recording or reproducing by optical means, e.g. recording using a thermal beam of optical radiation by modifying optical properties or the physical structure, reproducing using an optical beam at lower power by sensing optical properties; Record carriers therefor
    • G11B7/12—Heads, e.g. forming of the optical beam spot or modulation of the optical beam
    • G11B7/22—Apparatus or processes for the manufacture of optical heads, e.g. assembly
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/1477—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation making use of an absorber or impact modifier
    • B29C65/1483—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation making use of an absorber or impact modifier coated on the article
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
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    • B29C65/1638—Laser beams characterised by the way of heating the interface at least passing through one of the parts to be joined, i.e. laser transmission welding focusing the laser beam on the interface
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
    • B29C65/483—Reactive adhesives, e.g. chemically curing adhesives
    • B29C65/4845—Radiation curing adhesives, e.g. UV light curing adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
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    • B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
    • B29C66/122—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section
    • B29C66/1222—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least a lapped joint-segment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
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    • B29C66/1224—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least a butt joint-segment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/53—Joining single elements to tubular articles, hollow articles or bars
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    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
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    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
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Abstract

本发明涉及一种具有光学部件(22)与用于支撑光学部件的支撑部件(12)的光学单元(10)的制造方法。该方法中，使光学部件(22)与支撑部件(12)中至少一方的面变形后，固定该光学部件(22)与支撑部件(12)。

Description

光学单元及其制造方法 
技术领域
本发明涉及一种具有光学部件以及用于支撑光学部件的支撑部件的光学单元，以及其制造方法。 
背景技术
目前，使用光盘作为存储大容量信息的介质，为了在该光盘中高密度地存储信息并且准确地读出所存储的信息，构成光拾取器装置的多个光学部件分别都需要高精度。因此，专利文献1中，提出了对介在于物镜与用于保持该物镜的底座之间的粘接剂的厚度进行调整且对物镜的倾斜进行调整的技术。但该技术中，粘接剂的厚度处的偏差产生了新的物镜倾斜。另外，专利文献2中提出了以下技术：在物镜与用于保持该物镜的底座之间设置双金属材料或变形部件，通过向该变形部件付与热能，而使该变形部件变形来调整物镜的倾斜。同样，专利文献3、4中提出以下的技术：在物镜与用于保持该物镜的底座之间分别设置形状记忆合金、热敏材料所构成的支撑部件，向该支撑部件的一部分照射激光，而使该一部分形状恢复来调整物镜的倾斜。但该专利文献2～4中所公开的技术，在调整时将外力作用于底座并使其变形，因此物镜的倾斜调整需要很多时间。另外，必须在物镜与底座之间设置支撑部件，由于增加该支撑部件，构造变得复杂。 
专利文献1：特开平4-113521号公报 
专利文献2：特开平8-161755号公报 
专利文献3：特开平8-180422号公报 
专利文献4：特开平9-161755号公报 
发明内容
本发明的目的在于，提供一种结构简单且具有高可靠性，能够制作出光学部件的姿势的光学单元的制造方法，以及通过该方法所制作出的光学单元。 
为实现该目的，本发明相关的光学单元的制造方法，在具有光学部件以及用于支撑上述光学部件的支撑部件的光学单元中，在通过激光照射使上述光学部件与上述支撑部件相向之面中的至少一面变形后，且使变形的部件硬化而将上述光学部件以及上述支撑部件固定。 
另外，本发明相关的光学单元，相向的支撑部件与光学部件中的至少一方被突出，通过上述突出，在上述光学部件与上述支撑部件之间具有间隙的状态下进行固定，由波长810nm的近红外区域的光透过80％以上的材料形成的光学部件、和由波长810nm的近红外区域的光吸收80％以上的材料形成的支撑部件被固定。 
通过本发明，能够制造出光学部件的姿势以高精度且高可靠性调整后的光学单元。 
附图说明
图1为表示通过本发明相关的调整装置进行姿势调整后的光学单元之一例的平面图。 
图2为表示沿着图1中所示的光学单元的II-II线的剖面图。 
图3为表示含有图1、2中所示的光学单元的姿势调整装置之构成的主视图。 
图4为对使用图3所示的姿势调整装置的光学单元的姿势调整方法进行说明的剖面图。 
图5为对使用图3所示的姿势调整装置的光学单元的姿势调整方法进行说明的剖面图。 
图6为对使用图3所示的姿势调整装置的光学单元的姿势调整方法进行说明的剖面图。 
图7为对使用图3所示的姿势调整装置的光学单元的姿势调整方法进行说明的剖面图。 
图8中示出了表示激光照射时间与透镜倾斜量的关系的曲线图。 
图9为表示透镜对底座的固定方法的剖面图。 
图10为表示透镜底座中所形成的用来设置紫外线固化树脂的沟的图。 
图11为沿着图10的XI-XI线的剖面图。 
图12为表示沟设置的其他方式的平面图。 
图13为表示沟设置的其他方式的平面图。 
图14为表示熔化了的透镜材料被沟所限制的状态的剖面图。 
图15为表示透镜姿势调整方法的处理的流程图。 
图16A为用于说明透镜姿势调整方法的图。 
图16B为用于说明透镜姿势调整方法的图。 
图17为含有其他形态的底座的光学单元的平面图。 
图18为沿着图17的XVIII-XVIII线的剖面图。 
图19为包括具有姿势调整用突起部的光学单元的一部分及其姿势调整方法的示意剖面图。 
图20为表示含有通过图19的方法进行姿势调整后的透镜的光学单元之一部分的剖面图。 
图21为说明将底座/透镜的一部分熔化并对透镜姿势进行调整的方法的剖面图。 
图22为与图21一起对使底座/透镜的一部分熔化来调整透镜姿势的方法进行说明的剖面图。 
图23为表示从下方给熔化位置照射激光的方法的剖面图。 
图24为表示相对底座而固定透镜的装置的图。 
图25为说明相对底座的透镜的固定方法的另一实施方式的剖面图。 
图26为与图25一起对使透镜相对于底座固定的方法的另一实施方式进行说明的剖面图。 
图中：10…调整装置，12…底座，14…光学部件，16…框架，18…框架部分，20…支撑部，22…透镜，24…球面部，26…外座圈部(コバ)，28…姿势调整装置，30…评价部，32…调整部，34…控制部，36…光轴，38…光源，40…光学单元，42…衍射光栅，44…移动装置，46…光学单元，48…透镜，50…透镜，52…受像部，54…加热装置，56…激光源，58…光学单元，60…激光，62…支撑部分，64…透镜部分，66…界面，68…加热中心部，70…环状凸部，72…紫外线固化树脂，74…紫外线照射器，76…紫外线，78…沟，80…沟，82…透镜中心轴，84…最大倾斜角方向，86… 底座，88…上内周部，90…下内周部，92…环状阶梯部，94…突起部，96…透镜外周面，98…底座内周面，100…熔化材料，102…凹凸，104…基台，106…旋转部件，108…电动机，110…加热源，112…底座部分，114…熔化了的底座材料，116…透镜外周面。 
具体实施方式
对照附图，对本发明相关的多个实施方式进行说明。另外，以下的说明中，同一符号表示同一部件或部分。另外，以下的说明中，使用了表示特定方向的用语(例如“上”、“下”或含有这些用语的其他用语)，但这仅仅是为了让本发明的理解更加容易，并不应当对权利要求中所记载的本发明的范围进行限定。进而，本申请中，光学部件的“姿势”是指与含有该光学部件的光学单元的光轴相对的倾斜。 
(实施方式1) 
参照图1与图2，由本发明的姿势调整装置进行姿势调整的光学单元，具有由未图示的基台或支撑部所固定支撑的支撑部件即底座12，以及由底座12所支撑的光学部件即光学部件14。实施方式中，底座12具有框架16。框架16具有在X方向上延伸的两个框架部分18、以及在与X方向正交的Y方向上延伸的两个框架部分18，这4个框架部分18的内侧形成有圆形的开口。4个框架部分18在内面的长边方向的中央部、分别具有向内侧突出的支撑部20。如图所示，将各个支撑部20的上面优选设置在低于框架16的上面的位置。 
光学部件14例如是透镜22。实施方式中，透镜22是平凸透镜，上面形成为平面，同时，下面具有由球面所形成的球面部24和围住球面部24的周围的一定厚度的外座圈部(コバ)26。如图所示，外座圈部26的外径φ1，小于在X方向与Y方向上分别相向的框架部分18之间的距离L1。另外，球面部24的外径φ2，小于在X方向与Y方向上分别相向的支撑部20之间的距离L2。 
底座12与透镜22由加热后可熔融的材料制造而成。底座12优选由可见光区域与近红外区域的光例如波长为约400～约1100nm的光可吸收约80％以上的材料形成。透镜22优选由可见光区域与近红外区域的光例 如波长为约400～约1100nm的光可透过约80％以上的材料形成。各种热熔化性材料中，实施方式中底座12使用玻璃化转变温度约为150℃的材料(例如非晶聚烯烃类树脂)，透镜22使用比底座12更容易熔化的玻璃化转变温度约为135℃的材料(例如液晶聚合物)。 
具有这样的构成的底座12与透镜22，如图所示，在底座12的中心与透镜22的中心相一致或几乎相一致的状态下，由底座12的4个支撑部20对透镜22的外座圈部26进行支撑。并且如后所述，检测出透镜22相对底座12的姿势并进行评价，基于该评价结果，调整透镜22相对底座12的姿势。 
图3中示出了姿势调整装置28。姿势调整装置28，具有对透镜22的姿势进行评价的评价部30、根据评价部30的评价结果来调整透镜22的姿势的调整部32、以及对评价部30与调整部32进行控制的控制部34。 
评价部30具有在由底座12所支撑的透镜22的两侧(附图中为上下)所设置的多个部件。实施方式中，评价部30具有沿着调整装置28的光轴36进行发光的照明部或光源38。光源38优选使用发射激光的激光装置。激光优选为具有可干扰性的例如氦氖激光。光源38与透镜22之间，设置有使光源38所出射的光以平行光形式入射到透镜22中的光学单元40。光学单元40具有1个或多个透镜。根据需要在光学单元中设置反射镜等其他光学部件。 
在透过透镜22的光的聚光位置或其附近设置有透射型衍射光栅42。衍射光栅42由在垂直于光轴36的面上所设置的透光性板构成，在与透镜22相向的主面或相反侧的主面上，等间隔形成有在垂直于光轴36的方向上延伸的多个沟。衍射光栅42与移动装置44相连结，基于该移动装置44的驱动，在垂直于光轴36的面上沿着垂直于光栅沟的方向移动。移动装置44优选使用压电器件。 
透过延伸光栅42的光所入射的光学单元46具有透镜48，其中入射从衍射光栅42所出射的光(衍射光)。实施方式中，按照来自衍射光栅42的0级次衍射光与+1级次衍射光，或0级次衍射光与-1级次衍射光，或错位(shearing)干涉像入射到透镜48的方式，决定衍射光栅42的光栅沟的大小、间距等条件。 
评价部30具有用于接收出射光学单元46所出射的光的检测部的摄像元件或受像部52。受像部52优选由电荷耦合元件(CCD)构成，接收入射到透镜48中的错位干涉像。 
控制部34与光源38、移动装置44、及受像部52电连接，在透镜22的姿势评价时，起动光源38。从光源38所出射的光，由入射光学单元40调整成平行光或大致平行光，经透镜22照射到衍射光栅42。由衍射光栅42形成的、0级次衍射光与+1级次衍射光、或0级次衍射光与-1级次衍射光在透镜48的光瞳面上叠加，发生错位干涉。错位干涉光由透镜48恢复为平行光或略平行光，并通过透镜50照射到受像部52。受像部52将照射在受像面上的错位干涉像所对应的信号输出给控制部34。 
控制部34在启动光源38的期间，驱动移动装置44，而使衍射光栅42在垂直于光轴36的方向上移动。其结果，在透镜22相对光轴36倾斜的情况下或在含有任意的像差(球差、彗差、像散、场曲、畸变(distortion)、色差)的情况下，错位干涉像中的各点的受光强度发生变化。利用该光强的变化，控制部34对透镜22的姿势进行评价。 
用于评价上述透镜22的姿势的方法与装置之一例，可以利用公知的各种评价方法与装置。例如，本发明中可以使用的理想的方法与构成，在特开2000-329648号公报及其对应的美国专利第6809829号中有详细的记载，通过引用将其内容包括到本专利申请中。 
参照图3～图5，透镜的姿势调整部32，具有分别设置在4个框架支撑部20的上方的加热装置54。实施方式中，加热装置54，具有能够发射出红外线激光的激光源56、以及对激光源56所发射的激光进行聚光的光学单元58，按照通过光学单元58将激光源56所出射的激光60聚光在支撑部20的上面支撑部分62与其相向接触的透镜部分64之间的界面66或其附近的方式设置。实施方式中，从激光源56所出射的激光60的波长为810nm。另外，将加热装置54调整为在透镜22上面的输出为0.5W，在界面66中的激光光斑径为0.1mm。 
姿势调整时，控制部34对通过后述的方法所选择的1个或多个加热装置54进行起动，从激光源56发射激光60。如图4与图5所示，所出射的激光60经光学单元58在界面66或其附近聚光，对与界面66相邻的支 撑部分62和与其相向的透镜部分64进行加热。此时，接受到激光60照射的支撑部分62的激光照射位置被加热。接下来，将在支撑部分62中集中的热传递给透镜部分64，对该透镜部分64进行加热。其结果如上所述，由于透镜部分64的玻璃化转变温度比支撑部分62的低，因此透镜部分64的位于光斑附近的部分热膨胀。通过其后的激光照射所产生的进一步加热，如图6以及图7所示，透镜部分64的加热中心部68发生热收缩而上方出现凹陷，同时位于加热中心部68处的透镜材料变为蒸气，由该蒸气压举起透镜22，加热中心部68周围的透镜材料向周围流出，在加热中心部68的周围形成环状的凸部70，从而相对于支撑部件62将透镜部分64相对举起。 
进行用于调查激光的照射时间与透镜的倾斜量之间的关系的实验。实验中所使用的底座与透镜的关系及材料如上所述。透镜外座圈部的外径φ1为2～8m，优选为3.8mm，透镜球面部的外径φ2为1.4～7.4mm，优选为3.2mm，相向的框架部分间的距离L1为2.2～8.2mm，优选为4mm。激光的波长为810nm，透镜外座圈部上面的激光输出为0.5W，界面中的激光光斑径为0.1mm。透镜的倾斜量α通过下面的公式1来定义，仅向相向的一对支撑部分中的一方照射激光并进行测定。激光的照射时间为1秒、1.5秒、2秒、2.5秒、3秒。 
[公式1] 
α＝δ/φ1 
α：倾斜量[弧度(radian)] 
δ：透镜相对底座的上升量 
φ1：透镜外座圈部的外径 
另外，公式中的倾斜量的单位由弧度表示，但图8中所示的值是变换成“度(degree)”后的值。 
图8的曲线图中示出了实验的结果。从该曲线图可以得知，透镜倾斜量与激光照射时间成正比关系，通过控制激光的照射时间，能够准确地调整透镜倾斜量。另外，在进行激光照射的说明中，将激光源56设置在透镜的上面侧，但也可以将激光源56设置在透镜的下面侧、外座圈部侧等处，只要能够在支撑部20的上面支撑部分62和与其相向接触的透镜部分 64之间的界面66或其附近聚光即可。 
实验中，对透镜的激光照射部分发生变形的状况进行观察。其结果，激光照射开始1秒钟后，位于激光照射位置的透镜部分融化且开始膨胀。之后，随着激光照射时间的经过，透镜部分的激光照射位置融化。如果激光照射1.5秒以上，透镜融化区域就会发生凹陷，该凹陷的大小，随着时间的经过而从激光照射位置的中心逐渐向径向外侧扩大。另外，流出到径向外侧的融化透镜材料的厚度(高度)随着时间的经过而增大。激光停止后，流出到周围的透镜材料固化。固化之后，将透镜从底座上分离，肉眼对两者的激光照射位置进行观察，结果发现透镜中形成有环状的突起。另外，底座的支撑部中可以看到烧过的痕迹，但没有发现形状的变形。 
(透镜的固定)将如上进行过倾斜调整的透镜22固定在底座12上。该固定优选使用紫外线固化树脂。该处理中，在上述透镜的倾斜调整之前，向底座12和透镜22的相向区域、例如图9所示那样、底座12的支撑部分62与透镜22的透镜部分64、或向底座12的支撑部20上的相向的底座内周面部分与透镜外周面部分之间所设置的紫外线固化树脂72，照射来自紫外线照射器74的紫外线76，而使该紫外线固化树脂72固化。这种情况下，倾斜调整时紫外线固化树脂72的一部分暴露在激光下，但其性状不会改变，通过之后的紫外线照射，毫无问题地进行固化。另外，紫外线固化树脂72可以在透镜22置载于底座12上之前涂布在支撑部分62上，也可以在透镜22置载在底座12上的状态下流入到支撑部分62和与其相向的透镜部分64之间。另外，以上关于透镜的固定的说明中，是在倾斜调整之前设置紫外线固化树脂72，但也可以在透镜的倾斜调整之后设置紫外线固化树脂72，只要在照射紫外线76之前就可以。 
为了在底座12的支撑部分62与透镜22的透镜部分64之间设置预先决定的适量的紫外线固化树脂，如图10与图11所示，优选在底座12的支撑部分62中在加热中心部68的两侧，对称地形成在X方向上平行延伸的一对沟78、与在Y方向上平行延伸的一对沟80，并在该沟78、80中设置紫外线固化树脂72。特别是在X方向上延伸的沟78，在将透镜22置载于底座12之后从其垂直相向面之间流入紫外线固化树脂72的情况下，由于树脂沿着该沟78流入到支撑部分62与透镜部分64之间，因此非常有 效。另外，不一定要设置两种沟78、80，还可以如图12与图13所示，只设置X方向的沟78或Y方向的沟80中的任一方。通过设置这样的沟，不但具有在支撑部分62与透镜部分64之间设置一定量的紫外线固化树脂72的优点，还如图14所示，由于该沟78、80的存在，能够将熔化了的透镜材料的扩大限制在一定的范围内，同时能够高效地增大该范围内的凸部70的高度。 
(处理)对倾斜调整处理进行说明。如图15所示，首先，在底座12上置载透镜22，测定底座12的倾斜量(步骤1)。倾斜量的测定，利用图3中所示的姿势调整装置28的调整部32与控制部34而进行，控制部34求出透镜的倾斜量。具体的说，根据光源38所出射的光透过透镜22后由受像部52受像的光斑位置距理想位置的偏差，求出透镜的倾斜量。接下来，控制部36决定倾斜角调整量(步骤2)。例如如图2、3所示，在透镜22由4个支撑部20支撑的状态下，如图16(A)、16(B)所示，透镜22的中心轴82相对光轴36倾斜了角度θ，最大倾斜角方向位于箭头84所示的方向。这种情况下，控制部34中决定最大倾斜角方向。接下来，确定需要进行最大高度调整量的透镜部分64(1)。接下来，计算出透镜部分64(1)的高度调整量δ1、和位于该透镜部分64(1)的两侧的透镜部分64(2)、64(3)的高度调整量δ2、δ3。接下来，根据控制部34中所存储的表示“激光照射时间与高度调整量”的关系的表格，决定与透镜部分64(1)、64(2)、64(3)的高度调整量对应的激光照射时间(步骤3)。另外，图8的曲线图示出了“激光照射时间与倾斜量”之间的关系，但“激光照射时间与高度调整量”也具有同样的直线关系，将该关系作为表格存储到控制部34的存储器(ROM)中。接下来，控制部34起动透镜部分64(1)、64(2)、64(3)的上方所设置的激光源56(步骤4)，给透镜部分64(1)、64(2)、64(3)加热从表中所得到的各个照射时间。照射激光的场所优选是透镜外座圈部的中央。这是由于，如果给接近透镜有效面的内周侧部分照射激光，就有可能给透镜有效面带来坏影响，如果给远离透镜有效面的外周侧部分照射激光，熔化了的透镜材料就有可能渗出到外座圈部的外侧。如上所述，被加热的透镜部分64(1)、64(2)、64(3)熔化，该熔化了的透镜材料流进透镜部分64(1)、64 (2)、64(3)和与其相向的支撑部分62之间，而使透镜部分64(1)、64(2)、64(3)上升。当激光照射结束时，控制部34再次测定透镜22的倾斜(步骤5)，并根据测定结果计算目标值(高度调整量δ1、δ2、δ3)与测定值(实际的上升量δ1’、δ2’、δ3’)之间的差，对该差的绝对值(|δ1-δ1’|、|δ2-δ2’|、|δ3-δ3’|)是否处于允许值ε内进行判断。允许值ε优选根据模拟的结果或多个实验结果求出。判断的结果如果是绝对值差处于允许值的范围内，则从紫外线光源74给设置在支撑部分62与透镜部分64之间的紫外线固化树脂72照射紫外线76，使该紫外线固化树脂72固化，由此相对于底座12将透镜22固定。但在目标值与测定值的绝对值差超过了允许值的情况下，根据激光照射后所进行的倾斜测定的结果，再次决定倾斜调整量与激光照射时间，调整必要透镜部分的高度。 
另外，以上的倾斜调整的说明中，对位于最大倾斜方向附近的透镜部分与位于其两侧的3个透镜部分的高度进行了调整，但也可以只对位于最大倾斜方向两侧的两个透镜部分64(1)、64(2)进行高度调整。 
上述实施方式1还可以在不脱离本发明的范围内，进行各种变形，例如以下所示的其他实施方式。 
(实施方式2) 
上述实施方式1中，采用相对于底座将透镜由4个点支撑的构成，但支撑点的数目并没有限制，只要具有底座能够稳定支撑透镜的构成就可以。例如图17所示，在环状或矩形的底座86中，形成具有比透镜外座圈部26的外径φ1大的内径的上部内周部88、具有比透镜外座圈部26的外径φ1小且比透镜球面部24的外径φ2大的内径的下部内周部90、以及设置在该上部外周部88与下部外周部90之间的环状阶梯部92，让该环状阶梯部92支撑透镜22的外座圈部26。这种情况下，与实施方式1一样，求出透镜22相对底座86的最大倾斜方向84。之后，与实施方式1一样，起动3个调整用激光源56来调整透镜部分64(1)、64(2)、64(3)的高度，或起动2个调整用激光源56来调整透镜部分64(1)、64(2)的高度，从而调整透镜12相对底座86的姿势。这种情况下，由于能够调整的场所不依赖于支撑点，因此能够进行更细的调整。 
(实施方式3) 
实施方式1中，与底座的透镜支撑部分相向的透镜部分，采用与支撑部分相同的平面，但也可以在透镜部分中设置突起部。这种情况下，例如图19与图20所示，在与底座12的支撑部分62相向的透镜部分64中，设置朝向支撑部分62突出的突起部94，通过将该突起部94加热熔化，来将该突起部94的高度从H减小到H’，从而调整相对于支撑部分62的透镜部分64的姿势。根据本发明人的实验，确认了激光照射时间与突起部的高度减少量(H-H’)之间存在一定的关系。因此在本实施方式的情况下，也将激光照射时间与高度减少量之间的关系存储到控制部的存储部中，根据该关系来决定必要调整量所对应的激光照射时间。另外，突起部94的横截面的形状可以采用圆形、椭圆形、矩形或其他任意形状。另外，对应1个支撑部分62的突起部94的数目并不仅限于1个，可以是多个。这种情况下，由于能够使用以前的透镜底座来实现本发明，因此可以不新设计透镜底座。 
(实施方式4) 
实施方式1～3中，让透镜的一部分熔化变形来调整透镜相对底座的姿势，但也可以将与底座相向的透镜的一部分或与透镜相向的底座的一部分或其双方加热变形，来调整透镜相对底座的姿势。例如，实施方式1～3中，透镜材料选择比底座材料的玻璃化转变温度低的材料，通过这样只让透镜熔化变形，但反之也可以是底座材料选择比透镜材料的玻璃化转变温度低的材料，通过这样只让底座的一部分熔化变形，从而调整透镜相对底座的姿势。例如，实施方式1的情况下，通过激光使底座12的支撑部分62加热膨胀，能够使与其相向的透镜部分64的高度上升，调整透镜22的姿势。另外，实施方式3的情况下，在底座12的支撑部分62中形成突起部，并通过使该突起部加热变形，从而能够降低与其相向的透镜部分64的高度，调整透镜22的姿势。进而，实施方式2的情况下，如图21与图22所示，给透镜22的外周面96或与其相向的底座内周面98或其双方照射红外线激光，使其熔化。并且通过熔化了的材料100固化时所产生的收缩变形，而使透镜22相对底座12的倾斜角发生变化，从而能够调整透镜22的姿势。 
(实施方式5) 
向底座与透镜的界面照射调整用激光的方向没有限制。例如，如图23所示，在底座的下方设置调整用激光源56，从下方向界面66照射激光60也可。但本实施方式的情况下，作为优选，底座1212由可见光区域与近红外区域的光例如波长为约400～约1100nm的光可透过约80％以上的材料形成，透镜22由可见光区域与近红外区域的光例如波长为约400～约1100nm的光可吸收约80％以上的材料形成。另外，可以在界面60的斜上方或斜下方或旁边设置激光源56，斜着对界面66照射激光60。 
(实施方式6) 
以上的实施方式中，照射了激光的表面部分、即底座的支撑部分或透镜的透镜部分或其双方的表面中，优选形成微小的凹凸(图4与图19中通过符号102来表示)。这种情况下，入射到具有凹凸的表面部分中的激光在此会损失很多能量，促进了该表面部分的加热。 
(实施方式7) 
将调整后的透镜固定在底座中的方法，并不仅限于使用紫外线固化树脂的粘合，还可以通过将底座的一部分加热熔化，并将该熔化了的底座材料固着在透镜的外周面上，来将透镜固定于底座。例如图24～图26所示的实施方式中，具有底座旋转机构120。底座旋转机构120具有固定基台104、及由该基台104按照以光轴36为中心可旋转的方式支撑的旋转部件106，该旋转部件106由底座12支撑。另外，旋转部件106与电动机108驱动连接，进而电动机108与控制部34驱动连接。另外，在底座12的上方设有加热源110，加热源110与控制部34相连接。加热源110能够使用发射红外线的激光源。这种情况下，可以从激光源向底座12以任意角度倾斜照射激光。这种构成中，当上述透镜的姿势调整结束时，控制部34驱动电动机108，使旋转部件106以及对其进行支撑的底座12进行旋转，同时起动加热源110，将与透镜外周面相向的底座部分112加热熔化。旋转部件106的旋转中，可以常时驱动加热源110对底座部分112连续进行加热，也可以间歇性停止加热源110而对底座部分112进行间歇加热。其结果，如图26所示，熔化了的底座材料114被埋入到透镜外周面116与底座12之间的空隙中，附着在透镜外周面116上，冷却后固定在透镜外 周面116上，对透镜12进行保持。 
(实施方式8) 
实施方式7中所说明的用于使底座以及透镜旋转的机构，同样能够应用于上述实施方式1～7。例如图3所示，如果将同样的旋转机构120应用于实施方式1，则调整用激光器56只需要1个就可以。另外，如果将旋转机构120应用于图17中所示的实施方式2，就能够对环状阶梯部92的任意部分进行加热。 
(其他) 
上述实施方式中，加热底座或透镜的机构主要使用红外线激光器，但也可以采用使用电阻加热器或电子束的加热器来代替。另外，为了防止透镜相对底座的移动，加热机构优选是非接触式的加热机构。 
另外，透镜材料与底座材料可以使用任意的热熔化材料。例如，透镜材料中，除了非晶聚烯烃类树脂之外，还可以使用聚碳酸酯(ポリカ一ボネ一ト)、甲基丙烯酸酯树脂等热熔性树脂。底座材料中，除了液晶聚合物之外，还可以使用聚碳酸酯(ポリカ一ボ一ト)、聚对苯二甲酸丁二醇酯树脂、聚对苯二甲酸乙二醇酯树脂、聚苯砜PPSF(Polyphenyl Sulfone)树脂。 
进而，以上的说明中，示出了平凸透镜作为透镜之一例，但本发明也可以应用于其他透镜(双凸透镜、弯月凸透镜、双凹透镜、平凹透镜、弯月凹透镜、非球面透镜、柱面透镜)的姿势调整。另外，以上的说明中对本发明应用于透镜的姿势调整的例子进行了介绍，但本发明还同样可以应用于其他光学部件或光学零件(例如衍射光栅、反射镜、滤光片、片门装置)的姿势调整。另外，本发明不但能够应用于光学单元中含有的光学部件的姿势调整，还能够应用于调整1个部件(第1部件)相对另一个部件(第2部件)的姿势的方法。这种情况下，将与第2部件相向的第1部件的一部分，或与第1部件相向的第2部件的一部分，或其双方如上所述进行加热变形，来调整第1部件相对第2部件的姿势。 
本专利申请主张基于日本专利申请第2004-365673号(申请日：2004年12月17日，发明名称：“光学装置及其调整方法”)的优先权，其内容通过该引用而全部包括在本说明书中。 

Claims (11)

1.一种光学单元的制造方法，该光学单元具有光学部件以及用于支撑上述光学部件的支撑部件，
在该制造方法中，在通过激光照射使上述光学部件与上述支撑部件相向之面中的至少一面变形后，且使变形的部件硬化而将上述光学部件与上述支撑部件固定。
2.如权利要求1所述的光学单元的制造方法，其特征在于：
向上述光学部件与上述支撑部件相向之面中的至少一面照射激光，使其变形。
3.如权利要求2所述的光学单元的制造方法，其特征在于：
将透过上述光学部件的激光照射到上述支撑部件，而使上述支撑部件变形。
4.如权利要求2所述的光学单元的制造方法，其特征在于：
将透过上述支撑部件的激光照射到上述光学部件，而使上述光学部件变形。
5.如权利要求2所述的光学单元的制造方法，其特征在于：
预备激光输出与激光照射时间及光学部件的变形量之间的关系的表格，基于上述光学部件相对上述支撑部件的倾斜和上述表格，来调整激光。
6.如权利要求2所述的光学单元的制造方法，其特征在于：
在上述光学部件与上述支撑部件之间设置紫外线固化树脂，在使上述光学部件与上述支撑部件中的至少一方变形后，向上述紫外线固化树脂照射紫外线。
7.如权利要求2所述的光学单元的制造方法，其特征在于：
上述光学部件由非晶聚烯烃树脂形成，上述支撑部件由液晶聚合物形成。
8.如权利要求2所述的光学单元的制造方法，其特征在于：
上述光学部件或上述支撑部件中的一方，由波长为相同于激光光源所射出的激光波长的可见光区域与近红外区域的光可透过80％以上的材料形成，上述支撑部件或上述光学部件中的另一方，由波长为相同于激光光源所射出的激光波长的可见光区域与近红外区域的光可吸收80％以上的材料形成。
9.如权利要求8所述的光学单元的制造方法，其特征在于：
激光光源所射出的激光波长为810nm。
10.如权利要求2所述的光学单元的制造方法，其特征在于：
测定上述光学部件相对上述支撑部件的倾斜，根据测定结果，决定上述光学部件与上述支撑部件相向之面中的至少一面的目标变形量，使至少一面变形后，再次测定上述光学部件相对上述支撑部件的倾斜，在测定结果未满目标值时，再次使至少一面变形。
11.一种光学单元，其特征在于：
相向的支撑部件与光学部件中的至少一方被突出，通过上述突出而在上述光学部件与上述支撑部件之间具有间隙的状态下，进行固定，由波长810nm的近红外区域的光透过80％以上的材料形成的上述光学部件、和由波长810nm的近红外区域的光吸收80％以上的材料形成的上述支撑部件被固定。
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