CN107249868A - 用于模制光学组件和光学组件的模制过程和装置 - Google Patents
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Abstract
一种包括聚合物的基本透明的光学组件(2)被模制。光学组件(2)在其表面(S)的相应部分上具有基本匹配的光栅压印(4),其中该压印(4)具有基本为零的相对定向角。基本透明的熔融聚合物被迫位于模制组件(5)的两个表面之间。熔融聚合物被迫与形成两个基本匹配的光栅(4'F、4'B)的表面调制相接触。对准部分被定位使得当基本透明的聚合物位于表面之间时可观察到与两个光栅(4'F、4'B)交互的光。当聚合物仍是液体时,模制组件(5)从当前配置被重新配置到其中由该两个光栅(4'F、4'B)所形成的条纹图案的条纹间隔基本最大的新配置,从而对准光栅(4'F、4'B)以具有基本为零的相对定向角。该新配置在聚合物固化时被维持。
Description
背景
光学组件可以被用在光学系统中以便以可预测和期望的方式来改变可见光的状态,例如用在显示系统中以使得期望的图像对用户可见。光学组件可以以反射、折射、衍射等方式与光交互。衍射在传播波与诸如障碍物或狭缝之类的结构交互时发生。衍射可以被描述为波的干涉,并且在该结构在大小上与波的波长相当时最显著。可见光的光学衍射归因于光的波的性质并且可被描述成光波的干涉。可见光具有在大约390和700纳米(nm)之间的波长,并且当传播的光遇到例如数值范围在100或1000nm级别的类似规模的结构时,可见光的衍射是最显著的。
衍射结构的一个示例是周期性结构。周期性结构可引起光的衍射,光的衍射通常在周期性结构具有与光的波长大小类似的空间周期时最显著。周期性结构的类型包括,例如,光学组件的表面上的表面调制、折射率调制、全息图等。当传播的光遇到周期性结构时,衍射使得光被分成不同的方向上的多个光束。这些方向取决于光的波长,因此衍射光栅引起多色(例如,白)光的色散,由此,多色光被分成在不同方向上行进的不同颜色的光束。
当周期结构是在光学组件的表面上时,其被称为表面光栅。当周期性结构是源自表面本身的调制时,其被称为表面起伏光栅(SRG)。SRG的一个示例是在光学组件的表面中的被均匀直槽间隔区域分开的均匀直槽。槽间隔区域在本文被称为“线”、“光栅线”和“填充区域”。SRG的衍射的性质取决于入射在光栅上的光的波长和SRG的各种光学特性(例如线间隔、槽深度和槽倾斜角)这两者。SRG具有许多有用的应用。一个示例是SRG光导应用。光导(在本文也称为“波导”)是一种被用于借助于在光导内的内部反射(例如全内部反射(TIR))来传送光的光学组件。光导可以被例如用于基于光导的显示系统中,以将期望的图像的光从光引擎传送到人眼以使得该图像对眼睛可见。可以将光导的表面上的输入耦合(incoupling)和输出耦合(outcoupling)SRG分别用于输入光到波导或从波导输出光。
表面光栅可以借助于合适的微制造过程被制造,以在基板上创建适合的表面调制。微制造是指微米规模和更小规模的期望结构的制造(诸如表面光栅)。微制造可以涉及在基板上的蚀刻和/或沉积(以及可能的对沉积在基板上的膜的蚀刻和/或沉积)以在基板上(或在基板上的膜上)创建期望的微结构。如本文所使用的,术语“图案化基板”或类似术语涵盖了所有这样的在基板或基板膜上的蚀刻/沉积。尽管用表面光栅图案化的基板可能适合用作光学系统本身中的光学组件,但是图案化基板也可被用作用于制造此类光学组件的生产模板(production master)。例如,一旦用表面光栅图案化,熔融二氧化硅基板(或类似物)就可然后被用作用于由聚合物模制光学组件的模制组件的一部分,例如,模制组件可被布置成在腔表面上提供具有表面光栅的模制腔。当液体聚合物被迫进入模制腔时,它被迫与表面光栅接触以便将表面光栅压印在聚合物中,然后聚合物固化以形成在其表面上压印有表面光栅的固体聚合物光学组件。因此,可以以廉价、快速和直接的方式使用相同的图案化基板来大规模制造大量的聚合物光学组件。
概述
提供本概述以便以简化的形式介绍以下在详细描述中进一步描述的一些概念。本概述并不旨在标识所要求保护主题的关键特征或必要特征,也不旨在用于限制所要求保护主题的范围。所要求保护的主题也不限于解决背景技术部分中指出的任何或所有缺点的实现。
第一方面涉及一种用于制造包括聚合物的基本透明的光学组件的模制过程。光学组件在其表面的相应部分上具有基本匹配的光栅压印。光栅压印具有基本为零的相对定向角。该过程包括以下步骤。基本透明的熔融聚合物被迫位于模制组件的两个表面之间。这些表面具有形成两个基本匹配的光栅的表面调制。熔融聚合物被迫与表面调制相接触,以便将光栅压印在聚合物中。模制组件可被配置为改变光栅的相对定向角。至少模制组件的对准部分是基本透明的。对准部分被定位使得当基本透明的聚合物位于表面之间时可从对准部分观察到与两个光栅交互的光,由此当光栅的相对定向角朝向零变化时形成可观察的条纹图案。条纹图案呈现随着相对定向角减小而增加的条纹间距。当聚合物仍是液体时,模制组件从当前配置被重新配置到其中条纹图案的条纹间隔基本最大的新配置,从而对准光栅以具有基本为零的相对定向角。该新配置在聚合物固化时被维持。
第二方面涉及一种用于模制包括聚合物的基本透明的光学组件的模制装置。光学组件在其表面的相对部分上具有基本匹配的光栅压印。光栅压印具有基本为零的相对定向角。该装置包括模制组件、驱动机制、光传感器、以及控制器。模制组件具有两个表面,这些表面具有形成两个基本匹配的光栅的表面调制。模制组件可被配置为改变光栅的相对定向角。驱动机制被耦合到模制组件并且可被控制以配置模制组件。至少模制组件的对准部分是基本透明的,该对准部分被定位使得当基本透明的聚合物位于表面之间时可从对准部分观察到与两个光栅交互的光,由此当光栅的相对定向角朝向零变化时形成可观察的条纹图案。条纹图案呈现随着相对定向角减小而增加的条纹间距。光传感器被配置为接收与两个光栅交互的至少一些光。当聚合物仍是液体时,控制器被配置为基于从图像传感器接收的感测数据来控制驱动机制,以将模制组件从当前配置重新配置到其中条纹图案的条纹间隔基本最大的新配置,从而对准光栅以具有基本为零的相对定向角。该新配置在聚合物固化时被维持。
还提供通过本文所公开的任何过程获得的产品。此类产品包括用于光学系统的光学组件,由聚合物形成的该光学组件是基本透明的,并且在其表面的相对部分上具有基本匹配的光栅,所述光栅具有零至千分之一度之内的相对定向角。
附图说明
为了帮助理解所述主题,现在将仅通过示例参考下述附图,其中:
图1A是光学组件的示意性平面图;
图1B是光学组件的示意性说明,该光学组件被示为与入射光交互并且是从侧面观看的;
图2A是直二元光栅的示意性说明,该直二元光栅被示为与入射光交互并且是从侧面观看的;
图2B是斜二元光栅的示意性说明,该斜二元光栅被示为与入射光交互并且是从侧面观看的;
图2C是突出的三角光栅的示意性说明,该突出的三角光栅被示为与入射光交互并且是从侧面观看的;
图3是光学组件的透视图;
图4A、4B和4C分别是模制装置的各部分的侧视图、平面图以及透视图;
图4D示出了在一个实施例的模制过程期间在不同时间点处观察到的条纹的各种视图;
图5是模制装置的框图;
图6A和6B是另一实施例的模制过程期间的模制装置的侧视图。
详细描述
图1A和1B分别从顶面和侧面示出具有外表面S的基本透明的光学组件2,诸如波导。表面S的至少一部分呈现形成是SRG的表面光栅4的表面调制。这样的部分被称为“光栅区域”。这些调制包括基本平行和细长(比它们的宽度长得多)的光栅线,并且在此示例中基本是直的(尽管它们一般不需要是直的)。
图1B示出光学组件2,并且具体而言是与传入照明光束I交互的光栅4,所述光束向内入射到SRG 4上。光I在该示例中是白色光,并且因而具有多种颜色分量。光I与光栅4交互,光栅将所述光分成向内定向到光学组件2中的几个光束。光I的一些也可作为反射光束R0被表面S反射回来。零阶模式向内光束T0和任何反射R0是根据衍射的一般原理以及其它非零阶(±n-阶)模式(其可被解释为波干涉)被创建的。图1B示出第一阶向内光束T1,T-1;将理解可以依据光学组件2的配置创建或不创建更高阶的光束。由于衍射的性质取决于波长,因此,对于更高阶的模式而言,入射光I的不同颜色分量(即波长分量)当存在时以相对于彼此而言不同的传播角度被分成不同颜色的光束,如图1B所示。
图2A-2C是不同的示例性SRG 4a-4c(在本文统称为4)的特写示意性截面图,所述SRG可由(在这些图中是从侧面观看的)光学组件2的表面S的调制形成的。光束用箭头标记,其厚度标记大致相对的强度(越高强度的光束以越厚的箭头示出)。
图2A示出直二元SRG 4a的示例。直二元光栅4a由在表面S中通过突出槽间隔区域9a被分开的一系列槽7a来形成,所述槽间隔区域在本文也被称为“填充区域”、“光栅线”或简称为“线”。光栅4a具有d的空间周期(称为“光栅周期”),其是调制形状在其上重复的距离。槽7a具有深度h,且具有基本直的壁和基本平的基底。这样,在图2A中填充区域具有高度h和在填充区域的高度h上基本均匀的标记为“w”的宽度(其中w是周期的某个分数:w=f*d)。
对于直二元光栅,壁基本垂直于表面S。出于这个原因,光栅4a引起垂直进入到表面的入射光I的对称衍射,其中由光栅4a所创建的每个+n阶模式光束(例如T1)具有与对应的-n阶模式光束(例如T-1)基本相同的强度,通常小于约入射光束I的强度的五分之一(0.2)。
图2B示出斜二元光栅4b的示例。斜光栅4b也是由表面S中的标记为7b的槽形成,所述槽具有由宽度w的线9b所分开的基本直的壁和基本平的基底。然后,与直图案4a相比较而言,所述壁相对于法线倾斜了一定量,在图2B中由角度α标记。当沿法线测量时槽7b具有深度h。取决于非零倾斜所进入的非对称性,行进离开倾斜方向的±n阶模式向内光束具有比它们的阶模式对应物更高的强度(例如在图2B的示例中,T1光束被定向离开倾斜的方向并且通常具有比T-1光束更大的强度,但是这取决于例如光栅周期d);通过增加倾斜达足够量,那些对应物可以基本被消除(即具有基本为零的强度)。T0光束的强度通常还可以通过斜二元光栅被大大减少,这样,在图2B的示例中,第一阶光束T1通常具有至多约入射光束I的强度的五分之四(0.8)的强度。
二元光栅4a和4b可以被看作是嵌入到表面S中的空间波形,该空间波形具有基本为方波的形状(具有周期d)。在光栅4b的情况下,所述形状是倾斜达α的倾斜方波形状。
图2C示出了突出的三角光栅4c的示例,其是突出的梯形光栅的特殊情况。三角4c是由表面S中的槽7c形成,所述槽的形状是三角形的(且因此具有可分辨的尖端)并且当沿法线测量时其具有深度h。填充区域9c采用了三角形、齿状突起(齿形)的形式,具有与法线成角度α(α是光栅4c的倾斜角)的中部。所述齿形具有由d(其是光栅4c的光栅周期)分开的各尖端,在齿形底部处为w并且在齿形的尖端处变窄到基本为零的宽度。对于图4c的光栅,w≈d,但通常可以是w<d。所述光栅是突起的,其中齿形的尖端在槽的尖端上延伸。构建突起的三角形光栅栅格是可能的,该图案基本消除了传输模式T0光束和模式光束,仅留下±n阶模式光束(例如仅有T1)。槽具有与中线成角度γ(壁角)的壁。光栅4c可以被看作是嵌入在S中的空间波形,所述空间波形具有基本三角的波形,其倾斜了α。
形成光栅4a-4c的槽和间隔区域构成表面调制。
其它类型的光栅也是可能的,例如,其它类型的梯形光栅图案(其可以在宽度上始终不变窄到零)、正弦光栅图案等,并具有可以容易地以适合的方式被定义的调制宽度。这样的其它图案还呈现了深度h、线宽w、倾斜角α和壁角γ,其可以以类似于图2A-C的方式被定义。
光栅4具有光栅向量(通常被标记为d),其大小(量级)是光栅周期d,并且在与形成该光栅的光栅线垂直的方向上——参见图1A。
在基于光导的显示应用(例如在其中SRG被用于进入显示系统的光导和从显示系统的光导出来的光的耦合,和/或被用于提供耦合到波导中的光束的光束扩张)中,d通常在约250和500nm之间,并且h在约30和400nm之间。倾斜角α通常在约-45和45度之间,并在光栅向量的方向上被测量。
图3A示出了光学组件2的透视图,该光学组件在该组件表面的相应部分上具有两个分开的光栅4F和4B,这两个光栅是相对的、基本平行的且基本平的。如图3A所示,这些是表面的前部和后部。光栅4B、4F中的每一个由基本平行、细长的光栅线和槽形成,并且在此示例中也基本是直的。光栅4B、4F具有相应的光栅周期dF、dB,其可以相同或可以不相同。光栅4B、4F可以是上文所描述的类型(并且可以,但不一定是相同的类型)。
光栅4F和4B具有平行于它们各自的光栅线延伸的相应的光栅向量dF,dB(前光栅向量和背光栅向量)。示出了平面3,其具有如虚箭头所示的法线(垂直于平面3的单位向量)。在图3A的示例中,由于前表面部分和后表面部分是基本平行的,所以它们具有与该平面基本相同的法线(≈),使得前表面部分和后表面部分和平面3都基本平行(更一般而言,针对非平行的表面部分,平面3可被定义为在前表面部分法线和后表面部分法线的向量和的大致方向上具有法线因为它代表那些法线的平均值的方向,在如此定义的情况下该法线被认为基本匹配于那些法线)。
向量15F、15B(如虚线箭头所示)位于平面3中,它们是前光栅向量dF和背光栅向量dB在平面3上的几何投射。投射15F、15B具有角距Δφ,该角距Δφ是在平面3中的角度(方位角),并且当沿着法线观察时该角距Δφ是dF和dB角距。角距Δφ是光栅4F、4B的相对定向的度量,并且角距Δφ在本文中是指光栅4F、4B的相对定向角。当Δφ=0时,至少沿着法线3’观察的情况下,光栅4F、4B的光栅线是对准的,并且光栅4F、4B被称为是对准的。在图3的示例中,由于前表面部分和后表面部分是基本平行的,所以当Δφ=0时从任何视点观察的情况下,光栅4F、4B都是对准的(更一般而言,当光栅4F、4B被布置在相对表面部分上时,这是为真的,使得它们相应的光栅线在Δφ=0时是平行的)。
如将会是显而易见的,Δφ的值影响光学组件2的光学特性。在基于波导的显示应用中,其中光学组件2形成基于波导的显示系统的一部分,光栅的未对准(即,在Δφ中从零偏差)可取决于光栅功能而导致不期望的图像失真。
现在将参考图4A-4D描述用于从聚合物模制图3所示类型的光学组件的模制过程,图4A-4D示出了在该过程期间模制装置1的各种视图。该聚合物是基本透明的,这使得该过程(尤其)适合用于模制基于波导的显示系统的波导(见上文)。
图4A从侧面示出了装置1。该装置包括块5F、5B(前、背),5U、5D(上、下—仅在图4A中可见)以及5L(左—仅在图4B中可见),其是由刚性材料形成的。附图标记5被用于统称各块。各块被布置成相接触以形成腔11(模制腔),且各块表面的区域(内表面区域)形成腔11的表面。刚性块5构成模制组件。
前块和背块的内表面区域的各部分被调制以在这些内表面部分中的每一个上形成相应的光栅4’F、4’B(前腔和后腔光栅),其具有分别对应于在图3中示出的光学组件2的光栅4F、4B的结构——在此情况下,每个腔光栅4’F、4'B由以基本平行、细长的和基本直的光栅线/槽的形式的表面调制形成,并分别具有周期dF、dB。这些内表面部分构成腔11的表面的相对部分,其也是基本彼此平行的。
腔光栅4’F、4’B可例如通过适合的微制造过程被图案化于前块5F和后块5B上,或者它们本身可根据被适当图案化的基板来模制。
当聚合物8处于熔融(因此是液体)状态时,注入组件10迫使聚合物8进入模制腔11(从图4B右侧观察)。以此方式,液体聚合物8被迫与前腔和后腔光栅4'F、4'B接触,即与形成这些光栅的槽和线接触,这具有压印聚合物8中的腔光栅4’F、4’B的结构的效果。块5具有足够的刚性以抵抗来自液体聚合物的力的失真,因此光栅被无失真地压印。这最终是藉此在光学组件2(其本身由聚合物8在固化时形成)上形成光栅4F、4B的机制,出于该原因,最终光学组件2的光栅4F、4B在下文中被称为前和后“压印光栅”或等效的“光栅压印”4F、4B。其上形成有压印光栅4F、4B的最终光学组件2的前表面部分和后表面部分对应于模制腔的前表面部分和后表面部分。当聚合物被允许固化于其中时,最终组件2的整体大小和形状与腔11的大小和形状相匹配。
在图4A-4D中,z方向是指相对于最终光学组件定义的法线的方向(在此示例中该方向垂直于其上形成有腔光栅4’F、4’B的腔表面部分),xy平面对应于图3的平面3(在此示例中它平行于那些腔表面部分),并且腔光栅4’F、4’B具有相对定向角Δφ’,Δφ’以与压印光栅4F、4B的相对定向角等效的方式被定义(即,如在xy平面上测量它们的角距)。
刚性块5的布置不是固定的:前块和背块5B、4F中的至少一者(在此示例中是背块5B)在维持模制腔11的完整性的同时仍易于进行xy旋转,因此,它可在继续将液体聚合物维持在腔11中的同时被旋转。背块5B的受控xy旋转是通过控制耦合到背块5B的适合的驱动机制来实现的。使用市场上可购得的驱动机制,控制背块5B的xy旋转来以受调节的方式以微量(千分之一或更小度数)影响背块5B的受控旋转是可能的。
通过调整前块5F和背块5B相对于彼此的xy定向角以便调整腔光栅4’F、4’B的相对定向角Δφ’,在聚合物8固化之前精确地对准腔光栅4’F、4’B(即以具有基本为零的Δφ’)是可能的。通过在聚合物固化时维持基本为零的Δφ’,光学组件2上的压印光栅4F、4B(形成于聚合物8完成固化之际)以相等精度被对准(即,基本为零的Δφ=Δφ’)。现在将参考图4C和4D描述藉此实现此精度对准的机制。
图4C示出了模制装置1的组件的透视图。光传感器6(也在图4A-4B中示出)位于模制腔5的前方以接收沿着视线(LOS,如虚线所示)向传感器传播的光,该视线穿过了在此示例中是前块4’F的一部分的模制组件5的部分7(对准部分)。LOS被定向为与腔光栅4F、4B两者相交。至少模制组件的对准部分7沿着LOS是基本透明的,使得与两个光栅交互的光可沿着该LOS传播出模制组件。
本公开认识到,当腔光栅4’F、4’B处于近似对准时,沿着LOS可观察到的可观察的条纹图案被形成。“条纹图案”指当光与两个基本匹配的光栅交互以创造具有条纹的图案时所创造的图案(在此情况下指,当沿着LOS观察时被感知为重叠的腔光栅4’F、4’B的图案),其条纹间距取决于光栅的相对定向角。条纹图案由一系列交替的亮条纹和暗条纹形成,其间隔随着腔光栅4’F、4’B的相对定向角朝向零变化而增加,在相对定向角为零处条纹间距变成最大(理论上的无限大是图案与恰好为零的相对定向角恰好对准)。“近似对准”指Δφ’在使条纹间距是可检测的近似于零的范围内(即,不过于接近于零,使条纹间隔太大而不可检测,但也不距零太远,使条纹间隔太小而不可检测)。
实际上,使用来自光栅的衍射光最好观察条纹图案。衍射光通常沿着与入射光大致相同的路径而在相反方向上传播。入射/衍射光延其传播的路径在图4A中被标记为I/D(R标记从背光栅4’B反射的光所沿的路径)。LOS基本平行于I/D,因此沿LOS可见的光将包括与腔光栅4’F、4’B两者交互的光,包括聚合物8在腔11中的情况(由于聚合物8也是基本透明的,因此允许此类光通过传感器6)。因此,传感器6能够接收来自模制腔内部的与腔光栅4’F、4’B两者交互的光。在图4A的示例中,该光将在通过前光栅4’F之前被后光栅4’B(反射光具有反射衍射模式)反射。
当相对定向角Δφ’≈(5/1000)°时,条纹图案将通常具有约2mm的条纹间隔,其可容易地被观察到。随着此角度Δφ’减小,条纹间隔增加到其变为基本最大的时间点——这是发生以下的时间点:因为条纹大于腔光栅,或者至少大于腔光栅的一部分(如果仅有该部分被观察到),所以条纹间隔过大导致图案不再可观察到。在条纹间距基本最大的时间点,Δφ’基本为零——实际上,为Δφ’不大于约(0.5*1/1000)°至(1/1000)°的情况。
现有模制过程被如下利用。在模制腔11中的聚合物8仍是液体时,如果前块5F和背块5B还未近似对准,则使前块5F和背块5B近似对准,从而条纹图案可沿LOS被观察到(当前腔配置)。然后将它们的相对定向角Δφ’微调直到条纹间隔变为基本最大,此时Δφ’基本为零(新的和最终腔配置)。在聚合物8固化以形成光学组件2的同时维持新配置(具有基本为零的Δφ’),并且在最终组件2中的压印光栅4F、4B的相对定向角Δφ基本为零(等于如在新的和最终配置中所达到的Δφ’)。
图4D示出了在模制过程期间的不同时间点处,对准部分7沿LOS的视图。条纹图案在这些时间点上是可见的,其呈现出变化的条纹间距D.最左视图表示在光栅处于近似对准的时间点处的视图。向右移动,示出了随着相对定向角Δφ’朝向零变化(D相应地增加)的各时间点处的视图,直到到达如最左侧视图(其表示处于或近似新的和最终配置的示例性视图)所示的D基本最大的时间点。
实际上,可通过装置的适合照明来增加条纹图案的可见性。例如,为了增强条纹图案的可见性,激光器(未示出)可被用于提供朝向对准部分7的光束。光束被反射地衍射到背光栅4’B的背面,而衍射光束然后朝向传感器6穿过前光栅4’F。光束扩展器(未示出)可被用于在光束到达对准部分7之前扩展该光束,以便增加在其上可见性增强的区域。例如,光束可被扩展以涵盖腔光栅4’F、4’B,以在腔光栅4’F、4’B的全部范围上提供条纹图案的增强的可见性。弯曲组件可使用弯曲模具(即其上形成有光栅4’F和4’B的模制组件的表面可以是弯曲的)来制成,由此曲率被赋予给了聚合物以及光栅4’f、4’B的结构。
图5是包括控制器20的模制装置1的框图,该控制器被连接以控制驱动机制22和注入组件10两者,并接收来自传感器6的感测数据。驱动机制被耦合于形成模制组件的一部分的背块5F、5B中的至少一者(在该示例中是背块5B)以便微调前腔光栅4’B和背腔光栅4’B的相对定向角Δφ’。一旦控制器控制了注入组件10迫使聚合物8注入腔11中,控制器20就可通过控制驱动机制22来自动地调整Δφ’。
控制器20接收来自传感器6的感测数据,并基于该感测数据调整前腔光栅4’B和背腔光栅4’F的相对定向角Δφ’,直到通过实施如上概述的规程使Δφ’基本为零。控制器可通过在处理器上执行的代码来实现。
在第一实施例中,传感器6包括相机形式的图像感测组件,其将沿LOS拍摄的对准部分7的图像提供给控制器20(此类图像捕捉图4D所示的视图)。该控制器包括图像识别模块,其对所接收的图像执行自动图像识别规程,以在图像中捕捉到条纹图案时检测条纹图案的条纹。控制器调整Δφ’直到图像识别规程的结果指示条纹间隔D为最大,并维持此Δφ’直到聚合物固化。
当用激光束照明时,条纹图案由与两个光栅交互的激光束的光形成。条纹图案在任一模具的任何表面上可能不是,也不需要是可见的,因为用扩展的激光束获得的条纹图案可被直接记录于像素化的检测器(例如,各个像素检测器的阵列),即被两个对准光栅反射回来的光发生干涉并在检测器的检测表面上创造条纹图案。检测器例如可以是相机的一部分。以此方式,在检测器的表面上而不是在模具的表面上观察到图案。检测器被用于检测在检测器上创造的条纹间隔,并基于检测到的条纹间隔来控制模制过程,以将光栅对准到最大条纹间距。
在第二实施例中,传感器6包括光电二极管,该光电二极管屏蔽除小针孔(例如,具有1mm(数量级)的直径)之外的周围的光,穿过该小针孔仅有一小部分的条纹图案是可观察的。即,因此光电二极管所接收的唯一的光来自于针孔大小的条纹图案的小的部分,使得一旦腔光栅近似对准,条纹就大于针孔。控制器20然后例如以均匀的速率改变Δφ’。随着腔光栅4’F、4’B被对准,条纹间距增加,这有效地导致条纹的移动(这在图4D中是明显的)。因此,随着Δφ’变化,光电二极管所接收的光的强度在高(当通过针孔仅可观察到亮条纹的一部分)和低(当通过针孔仅可感知到暗条纹的一部分)之间震荡。随着条纹间距增加,由于亮和暗条纹逐渐变大,该震荡的速率会降低,使得Δφ’基本变为零时震荡的速率最小——在第二实施例中,控制器调整Δφ’直到达到此最小震荡速率,并维持该Δφ’直到聚合物固化。
在一些光学组件中,可能期望需要具有附加表面光栅,该附加表面光栅具有相对定向角,该相对定向角不会以大于基本为零的量偏离于非零量Φ(即,该相对定向角是Φ+Δφ,其中Δφ是基本为零的)。在此情况下,如图4C所示的光栅4’F、4’D可按与上文所描述的相同的方式使用,其中第一其他光栅形成在前块的内表面的不同部分上,该第一其他光栅被定向在相对于4’F成角Φ1处,并且第二其他光栅形成在后块的内表面的不同部分上,该第二其他光栅被定向在相对于4’B成角Φ2处。角度Φ1、Φ2使得Φ=|Φ2-Φ1|,Φ可使用常规技术(例如常规微制造技术)来达到高精度。当使用上述技术将光栅4’F、4’B对准以具有基本为零的相对定向角Δφ’(相对于彼此)时,该其他光栅将具有相对于彼此的定向角(其基本为Φ),即,该定向角最多以Δφ’级别的量偏离于Φ(当然Δφ’基本为零)。由于当聚合物为液体时其以与类似于4’F、4’B的方式被迫与其他光栅相接触,这些其他光栅也将被压印在聚合物中,使得这些其他光栅在被压印在聚合物时也基本具有所需的相对定向角Φ。
图6A和6B例示了替换模制过程。在此过程中,有透明基板,诸如玻璃或适合的塑料板30之类。基板上的薄层聚合物被用于复制来自模具的光栅(即,该基板充当光学组件的“脊柱”),并且光栅被形成在基板上的薄层聚合物8上。
图6A示出了初始布置中的替换模制装置1’,其中板30被设置在两个块5F、5B之间,该板30具有沉积在其外表面的各部分上的薄层液体聚合物8。这些块可与图4A-C的装置基本相同,具有等效的光栅4’F、4’B。块5F、5B然后被迫朝向彼此,使得光栅4’F、4’B被迫与液体聚合物层接触,如图6B所示。以此方式,它们的结构被压印在聚合物层中。然后使用由光栅4’F、4’B形成的条纹图案将调制4’F、4’B的相对定向角改变成基本为零,并且在聚合物层固化时维持该相对定向角。最终光学组件包括板30和板表面上的固化的聚合物层。
注意,在此情况下,聚合物在其中被压印的区域不必被密封,并且对准部分可替换地是组件5F和5B之间的未覆盖的间隙(例如,传感器6可位于装置1’之下以接收两个光栅4’F、4’B所反射的光,对准部分是装置1’底部处5F和5B之间的间隙)。
如将会是显而易见的,替换装置1’不需要注入组件,而是具有与图5所示的配置相似的配置。
虽然在上文中,示例性光栅4F、4B(等效4’F、4’B)由于它们两者都由基本直的光栅线形成的事实而相匹配,但是一般而言,被认为是“基本匹配”的光栅并不必由直的光栅线形成,也不必由相同形状的弯曲光栅线形成。一般而言,两个光栅“基本匹配”提供了它们相应的结构的某些部分足够相似,使得创建通过覆盖这些部分来呈现可分辨的条纹间距(即使它们结构的其他部分可能明显不同)的可观察的条纹图案是可能的。
注意,对准光栅不需要重叠,前提是接收在空间位置处(例如在检测器处)互相交互的光(例如,被反射回)是可能的,以便在该位置处形成条纹图案。
虽然在上文中,光栅形成于相对的、基本平行的表面上,但是一般而言术语“相对表面部分”(或类似物)涵盖不平行的表面部分。.注意,参考图3B的上述的两个光栅之间的相对定向角(方位角)的定义可被应用于在非平行的表面部分上的各光栅。
虽然已经参考相对光栅描述了上述内容,但是此技术可被应用于非相对的光栅,由此,例如由在两个光栅上通过反射引导的光束形成条纹图案,并且该光束因此与两个光栅交互。
腔光栅4’F、4’B(以及因此压印光栅4F、4B)的形状可以为二元形(倾斜/非倾斜)、正弦形、梯形(三角形)(等等),而不需要具有彼此相同的形状、倾斜角α、宽度w、深度h等(虽然彼此相同并不被排除)。
在上述考虑基本软件实现的控制器20时,控制器的功能可以使用软件、固件、硬件(例如,固定逻辑电路)、或这些实现的组合来实现。如本文所使用的术语“模块”、“功能”、“组件”和“逻辑”(在适用时)一般表示软件、固件、硬件或其组合。在软件实现的情况下,模块、功能或逻辑表示当在处理器(例如,一个或多个CPU)上执行时执行指定任务的程序代码。程序代码可被储存在一个或多个计算机可读存储器设备中。下面所描述的技术的特征是平台无关的,意味着所述技术可以在具有各种处理器的各种商用计算平台上实现。
例如,装置还可包括使得装置的计算机的硬件执行操作的实体(例如软件),例如处理器、功能块,等。例如,计算机可包括计算机可读介质,其可被配置用于维护使得计算机(且尤其是计算机的操作系统和相关联的硬件)执行操作的指令。因此,这些指令用于配置操作系统和相关联的硬件来执行这些操作,并以此方式致使操作系统和相关联的硬件变换以执行各功能。可由计算机可读介质通过各种不同配置将指令提供给计算机。
一种这样的计算机可读介质配置是信号承载介质,并因此被配置来将指令(例如,作为载波),例如通过网络,传送到计算设备。计算机可读介质还可被配置为计算机可读存储介质并且因而不是信号承载介质。计算机可读存储介质的示例包括随机存取存储器(RAM)、只读存储器(ROM)、光板、闪存、硬板存储器、和其他可使用磁、光以及用于存储指令和其他数据的其他技术的存储器设备。
此外,虽然上述对准过程是自动化的,但是手动或部分手动过程并不被排除。
在上述各个方面的实施例中,当腔被重新配置时可捕捉条纹图案的图像,并且可执行自动图像识别规程以检测图像中的条纹图案,重新配置的步骤基于图像识别规程的结果。
当腔被重新配置时,仅一小部分的条纹图案的光可被感测到,重新配置的步骤基于该光的强度改变的速率。
每个光栅可基本平行于平面放置,并且当沿垂直于平面的方向观察时,光栅可以不彼此重叠或可以仅部分地彼此重叠。
光栅可用扩展的激光束照明,条纹图案由与两个光栅交互的激光束的光形成。激光束的光可例如在检测器处被接收,所接收的光的一部分已经被光栅中的一个反射而该光的另一部分已经被光栅中的另一个反射,由此该部分和另一部分在检测器处发生干涉以在检测器的检测表面上形成条纹图案。检测器的输出可被用于控制重新配置的步骤。
腔表面的相对部分可以是基本平行的,使得经模制的光学组件的表面的相对部分是基本平行的。
第一和第二其他光栅可被形成于腔表面的其他相对部分上,第一其他光栅相对于光栅中的一个具有第一定向角Φ1,而第二其他光栅相对于光栅中的另一个具有第二定向角Φ2,使得在新配置中第一和第二其他光栅被压印在聚合物中并具有基本为|Φ2-Φ1|的相对定向角。
模制组件中的至少一个表面可以是弯曲的,使得聚合物以弯曲的配置被固化。
模制组件可被布置成提供模制腔,其表面是模制腔的,并且聚合物可被迫进入模制腔中以迫使聚合物与表面调制相接触,当腔中的聚合物仍是液体时,模制组件被重新配置成新配置。
聚合物可被布置在基本透明的基板的表面上的各层中,由此光栅被压印在各层中,当各层仍是液体时,模制组件被重新配置成新配置,该光学组件包括基板和一次固化的各层。
光传感器可包括当腔被重新配置时捕捉条纹图案的图像的相机,控制器可包括执行自动图像识别规程以检测图像中的条纹图案的图像识别模块,并且控制器可基于图像识别规程的结果来重新配置该腔。
当腔被重新配置时,光传感器可感测仅一小部分的条纹图案的光,并且控制器可基于该光的强度改变的速率被重新配置。
根据第三方面,在光学系统中使用的光学组件是基本透明的,并且具有两个相对的外表面。至少每个相对表面的相应部分由相应光栅被压印于其中的聚合物形成。光栅基本彼此匹配并且具有零至千分之一度之内的相对定向角。
相对定向角可例如为零至千分之0.5度之内。
相对表面部分可以是基本平行的。
光学组件可被用作显示系统中的波导以将图像的光传送到用户的眼睛,例如可由用户穿戴的可穿戴显示系统。
光栅的形状可以是二元形、梯形或正弦形。
本主题的另一方面涉及一种用于模制包含聚合物的基本透明的光学组件的模制装置,所述光学组件在其表面的相对部分上具有基本匹配的光栅压印,其中所述光栅压印具有基本为零的相对定向角,所述装置包括:具有两个表面的模制组件,所述表面具有形成两个基本匹配的光栅的表面调制,其中所述模制组件是可被配置的以改变所述光栅的所述相对定向角;被耦合到模制组件的所述驱动机制可控制以配置所述模制组件;其中至少所述模制组件的对准部分是基本透明的,所述对准部分被定位使得当所述基本透明的聚合物位于所述表面之间时可从所述对准部分观察到与两个光栅交互的光,由此当所述光栅的所述相对定向角朝向零变化时形成可观察的条纹图案,所述条纹图案呈现随着所述相对定向角减小而增加的条纹间距,所述装置进一步包括:所述光传感器被配置为接收与两个光栅交互的至少一些光;以及所述控制器被配置为在所述聚合物仍是液体时基于从所述图像传感器接收的感测数据来控制所述驱动机制,以将所述模制组件从当前配置重新配置到其中所述条纹图案的所述条纹间隔基本最大的新配置,从而对准所述光栅以具有基本为零的相对定向角,其中所述新配置在所述聚合物固化时被维持。
又一方面涉及一种用于由聚合物模制基本透明的光学组件的模制过程,所述光学组件在其表面的相对部分上具有基本匹配的光栅压印,其中所述光栅压印具有基本为零的相对定向角,所述过程包括:迫使基本透明的熔融聚合物进入由模制组件提供的模制腔中,所述腔表面具有在所述腔表面的相对部分上形成两个基本匹配的光栅的表面调制,所述熔融聚合物被迫与所述表面调制相接触以便将所述光栅压印在所述聚合物中,其中所述腔是可配置的以改变所述光栅的所述相对定向角;其中至少所述模制组件的对准部分是沿与两个光栅交互的视线基本透明的,使得当所述基本透明的聚合物位于所述腔内时,沿所述视线可观察到与两个光栅交互的光,由此当所述光栅的所述相对定向角朝向零变化时形成可观察的条纹图案,所述条纹图案呈现随着所述相对定向角减小而增加的条纹间距,所述过程进一步包括:当所述腔内的所述聚合物仍是液体时,将所述腔从当前配置重新配置到其中所述条纹图案的所述条纹间隔基本最大的新配置,从而对准所述光栅以具有基本为零的相对定向角,其中所述新配置在聚合物固化时被维持。
尽管用结构特征和/或方法动作专用的语言描述了本发明主题,但可以理解,所附权利要求书中定义的主题不必限于上述具体特征或动作。更确切而言,上述具体特征和动作是作为实现权利要求的示例形式公开的。
Claims (15)
1.一种用于制造包括聚合物的基本透明的光学组件的模制过程,所述光学组件在其表面的相应部分上具有基本匹配的光栅压印,其中所述光栅压印具有基本为零的相对定向角,所述过程包括:
迫使基本透明的熔融聚合物位于模制组件的两个表面之间,所述表面具有形成两个基本匹配的光栅的表面调制,所述熔融聚合物被迫与所述表面调制相接触以便将所述光栅压印在所述聚合物中,其中所述模制组件是可配置的以改变所述光栅的所述相对定向角;
其中至少所述模制组件的对准部分是基本透明的,所述对准部分被定位使得当所述基本透明的聚合物位于所述表面之间时可从所述对准部分观察到与两个光栅交互的光,由此当所述光栅的所述相对定向角朝向零变化时形成可观察的条纹图案,所述条纹图案呈现随着所述相对定向角减小而增加的条纹间距,所述过程进一步包括:
当所述聚合物仍是液体时,将所述模制组件从当前配置重新配置到其中所述条纹图案的所述条纹间隔基本最大的新配置,从而对准所述光栅以具有基本为零的相对定向角,其中所述新配置在聚合物固化时被维持。
2.如权利要求1所述的模制过程,其特征在于,包括当所述腔被重新配置时捕捉所述条纹图案的图像,并执行自动图像识别规程以检测所述图像中的所述条纹图案,其中重新配置的步骤基于所述图像识别规程的结果。
3.如权利要求1所述的模制过程,其特征在于,包括当所述腔被重新配置时,感测仅一小部分的所述条纹图案的光,其中重新配置的步骤基于此光的强度改变的速率。
4.如权利要求1所述的模制过程,其特征在于,每个所述光栅都基本平行于平面放置,并且当沿垂直于所述平面的方向观察时,所述光栅不彼此重叠或仅部分地彼此重叠。
5.如权利要求1所述的模制过程,其特征在于,用扩展的激光束照明所述光栅,所述条纹图案由与两个光栅交互的所述激光束的光形成。
6.如权利要求5所述的模制过程,其特征在于,包括:
在检测器处接收所述激光束的所述光,所接收的光的一部分已经被所述光栅中的一个反射而所述光的另一部分已经被所述光栅中的另一个反射,由此所述部分和所述另一部分在所述检测器处发生干涉以在所述检测器的检测表面上形成所述条纹图案;以及
使用所述检测器的输出来控制所述重新配置的步骤。
7.如权利要求1所述的模制过程,其特征在于,所述腔表面的所述相对部分是基本平行的,使得所述经模制的光学组件表面的所述相对部分是基本平行的。
8.如权利要求1所述的模制过程,其特征在于,第一和第二其他光栅被形成于所述腔表面的其他相对部分上,所述第一其他光栅相对于所述光栅中的一个具有第一定向角Φ1,而所述第二其他光栅相对于所述光栅中的另一个具有第二定向角Φ2,使得在所述新配置中所述第一和第二其他光栅被压印在所述聚合物中并具有基本为|Φ2-Φ1|的相对定向角。
9.如权利要求1所述的模制过程,其特征在于,所述模制组件中的至少一个所述表面是弯曲的,使得所述聚合物以弯曲的配置被固化。
10.如权利要求1所述的模制过程,其特征在于,所述模制组件被布置成提供模制腔,所述表面是所述模制腔的,并且其中所述聚合物被迫进入所述模制腔以迫使所述聚合物与所述表面调制相接触,当所述腔中的所述聚合物仍是液体时,所述模制组件被重新配置成所述新配置。
11.如权利要求1所述的模制过程,其特征在于,所述聚合物被布置在基本透明的基板的所述表面上的层中,由此所述光栅被压印在所述层中,当所述层仍是液体时,所述模制组件被重新配置成所述新配置,其中所述光学组件包括所述基板和一次固化的所述层。
12.一种用于模制包括聚合物的基本透明的光学组件的模制装置,所述光学组件在其表面的相应部分上具有基本匹配的光栅压印,其中所述光栅压印具有基本为零的相对定向角,所述装置包括:
模制组件,所述模制组件具有两个表面,所述表面具有形成两个基本匹配的光栅的表面调制,其中所述模制组件是可被配置的以改变所述光栅的所述相对定向角;
被耦合到所述模制组件的驱动机制,所述驱动机制可控制以配置所述模制组件;
其中至少所述模制组件的对准部分是基本透明的,所述对准部分被定位使得当所述基本透明的聚合物位于所述表面之间时可从所述对准部分观察到与两个光栅交互的光,由此当所述光栅的所述相对定向角朝向零变化时形成可观察的条纹图案,所述条纹图案呈现随着所述相对定向角减小而增加的条纹间距,所述装置进一步包括:
光传感器,所述光传感器被配置为接收与两个光栅交互的至少一些光;以及
控制器,所述控制器被配置为在所述聚合物仍是液体时基于从所述图像传感器接收的感测数据来控制所述驱动机制,以将所述模制组件从当前配置重新配置到其中所述条纹图案的所述条纹间隔基本最大的新配置,从而对准所述光栅以具有基本为零的相对定向角,其中所述新配置在所述聚合物固化时被维持。
13.一种在光学系统中使用的光学组件,其特征在于,所述光学组件是基本透明的并且具有两个相对外表面,其中至少每个所述相对表面的相应部分由相应光栅被压印于其中的聚合物形成,其中所述光栅基本彼此匹配并且具有零至千分之一度之内的相对定向角。
14.如权利要求13所述的光学组件,其特征在于,所述相对定向角为零至千分之0.5度之内。
15.如权利要求13所述的光学组件,其特征在于,当被用作可穿戴显示系统中的波导时以将图像的光传送到穿戴者的眼睛。
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