JP2022072280A - Method for manufacturing light reflection element used in optical image forming device - Google Patents

Abstract

To provide a method for manufacturing a light reflection element which is used in an optical image forming device, with which it is possible to improve the accuracy of end surface of the light reflection element, and even when juxtaposing a plurality of light reflection elements or optical image forming devices, it is possible to provide a clear real image in which the light reflection layers of the adjacent light reflection elements or optical image forming devices are aligned.SOLUTION: A first to a fourth support member 15 to 18 are pressed against and fastened via a peelable second adhesive to upper and lower surfaces A and B in a thickness direction of a raw laminate 13 created by laminating and fastening, via a first adhesive, a plurality of rectangular transparent plates 11 in which a light reflection layer 12 is formed, and to surfaces C and D orthogonally facing said surfaces, respectively, so as to form a first laminate block 19. The first laminate block 19 is cut off in a direction orthogonal to the light reflection layer 12 to manufacture a light reflection element starting material 25. The cut surface of the light reflection element starting material 25 is polished while the cut pieces 21 to 24 of the first to fourth support members 15 to 18 are fastened, and chips when cut and polished are eliminated.SELECTED DRAWING: Figure 1

Description

The present invention relates to an optical imaging apparatus in which paired light reflecting elements having a large number of light reflecting layers arranged in parallel at predetermined intervals perpendicular to one surface are arranged so that the light reflecting layers are orthogonal to each other. The present invention relates to a method for manufacturing a light reflecting element to be used.

As shown in Patent Document 1, the applicant has formed the first and second transparent flat plates by arranging a large number of strip-shaped plane light reflecting layers perpendicular to one surface of the transparent flat plate at a constant pitch. We have proposed an optical imaging device in which one surface side of each of the first and second optical control panels is formed by using an optical control panel with the plane light reflecting layers orthogonal to each other. Further, Patent Document 2 discloses a method for manufacturing an optical imaging device for forming an image of an object as a real image at a position symmetrical with respect to a plane on the opposite side. Further, a large-scale optical imaging device is disclosed in Patent Documents 3 and 4.

International Publication No. 2009/131128 Japanese Patent No. 5085767 International Publication No. 2013/179405 Japanese Unexamined Patent Publication No. 2013-101230

However, in the method for manufacturing an optical imaging device described in Patent Documents 1 and 2, even if the accuracy of the light reflecting element (optical control panel) used in the optical imaging device is slightly different, one optical imaging device is used. Since the corner portion is not used in the apparatus, no problem occurs, but as described in Patent Documents 3 and 4, a plurality of optical imaging devices are bonded (tied) to manufacture a large optical imaging device. Then, it was necessary to accurately match the end faces of the individual optical imaging devices.
Further, if the optical imaging device is once completed and then polished to match the vertical and horizontal dimensions, there have been problems such as chipping of the light reflecting element and misalignment of the light reflecting element constituting the optical imaging device.

The present invention has been made in view of such circumstances, and the dimensional accuracy of the end face of the light reflecting element is improved, and even if a plurality of light reflecting elements or optical imaging devices are arranged side by side, the adjacent light reflecting element or optical imaging device can be used. It is an object of the present invention to provide a method for manufacturing a light reflecting element used in an optical imaging device capable of providing a clear real image by arranging light reflecting layers correctly.

The method for manufacturing a light-reflecting element according to the present invention according to the above object is a method for manufacturing a light-reflecting element used in an optical imaging device that forms an image of an object arranged in one side space as a real image in the other side space. hand,
A plurality of (usually about 200 to 1000) rectangular (preferably square) transparent plates having a light reflecting layer formed on at least one surface thereof are made of a first piece that is resistant to peeling in a direction orthogonal to the light reflecting layer. The original laminated body is formed by laminating and fixing via the adhesive of the above, and the first to the upper and lower surfaces A and B of the original laminated body, and the surfaces C and D facing orthogonal to the surface A and the surface D, respectively. The first step of forming the first laminated block in which the fourth support member is pressed and fixed via the removable second adhesive, and the first step.
A second step of cutting the first laminated block together with the first to fourth support members at equal intervals in a direction orthogonal to the light reflecting layer to manufacture a light reflecting element raw material.
The cut surface of the cut light-reflecting element raw material is polished in a state where the cut pieces of the first to fourth support members are fixed (the thickness of the light-reflecting element raw material produced thereby is t). Third step and
A plurality of light reflecting element materials polished in the third step and from which the cut pieces of the first to fourth support members have been removed are stacked and fixed with a peelable third adhesive to form a second laminated block. The fourth step of forming and
The fifth step of polishing the facing surfaces C'and D'of the second laminated block to adjust the width of the light reflecting element material to a specified value.
It has a sixth step of melting the third adhesive to form the light reflecting element.

After that, it is also possible to join the two light-reflecting elements with a transparent fifth adhesive so that the light-reflecting layers are orthogonal to each other in a plan view to form an optical imaging device. The ends of the elements are combined to form a larger light-reflecting element, and then two large-sized light-reflecting elements are joined so that their reflecting surfaces (light-reflecting layers) are orthogonal to each other to form a large-sized optical imaging device. You can also do it. Further, a plurality of optical imaging devices can be arranged side by side with their ends abutting to form a large-sized optical imaging device.
In the method for manufacturing a light reflecting element according to the present invention, after the fourth step and before the fifth step, the second laminated block is surrounded orthogonally to the surface C'and the surface D'to be polished. At least the end portions of the surfaces E to H may be reinforced with a peelable fourth adhesive (reinforcing step 4A around the polished surface).

In the method for manufacturing a light reflecting element according to the present invention, a fourth adhesive that can be peeled off from a surface E to a surface H that is orthogonal to the surface C'and the surface D'is used before the fifth step. It is preferable to join the eighth reinforcing support member to prevent the occurrence of defects in the second laminated block. In this case, the reinforcing step 4A around the polished surface is not performed.

In the method for manufacturing a light reflecting element according to the present invention, the facing 6th and 8th reinforcing support members surrounding or sandwiching the 2nd laminated block are used for the facing 5th and 7th reinforcing members. It is preferable that they are arranged so as to sandwich the support member.

In the method for manufacturing a light reflecting element according to the present invention, where h is the thickness of the original laminated body, the width w of the light reflecting element obtained from the polished second laminated block is h ± 0.5 mm. It is preferable that the shape of the light reflecting element in a plan view is a square within the above range. As a result, a pair of light reflecting elements used in the optical imaging device can be manufactured at the same time.

Further, in the method for manufacturing a light reflecting element according to the present invention, the removal of the cut pieces of the first and second support members may be performed after the fifth step.
In the present invention, as the first adhesive (fifth adhesive), for example, a thermosetting resin-based adhesive, an epoxy-based adhesive, an elastomer-based adhesive having self-hardening or thermosetting property can be used, but the rectangular transparent. Other adhesives may be used as long as the plates can be firmly bonded. Further, as the second to fourth adhesives, it is preferable to use a thermoplastic adhesive or a water-soluble adhesive that melts when heated (for example, heated to 80 ° C.). Not limited.

In the method for manufacturing a light-reflecting element according to the present invention, when the end portion of the light-reflecting element material is polished, the rectangular transparent plate is less likely to be chipped or displaced, and a light-reflecting element with high dimensional accuracy can be manufactured. This makes it possible to easily manufacture a large-sized optical imaging device. That is, since a light reflecting element having the same dimensions can be manufactured, a large number of light reflecting elements can be arranged side by side to manufacture a large light reflecting element, and the light reflecting elements are bonded together so that the light reflecting layers are orthogonal to each other to form a large optical connection. An image device can be configured.
Further, since the accuracy of each light reflecting element is high, for example, four, nine, or sixteen light reflecting elements can be arranged on a plane to form a larger light reflecting element. Further, it becomes easy to manufacture a large-sized optical imaging device by tiling an optical imaging device in which a light reflecting element is combined.

(A) is an explanatory diagram of a glass plate material, and (B) is an explanatory diagram of a first step of a method for manufacturing a light reflecting element according to an embodiment of the present invention. It is explanatory drawing of the 2nd process of the manufacturing method of the said light reflection element. (A) and (B) are perspective views and side views of the light reflecting element raw material manufactured in the second step, respectively. (A) is a perspective view of a light-reflecting element material in which cut pieces of the first to fourth support members are removed from the same light-reflecting element raw material, and (B) is a first formed by stacking a plurality of the same light-reflecting element materials. It is a perspective view of 2 laminated blocks. (A) is an explanatory view in which the fifth to eighth reinforcing support members are joined to the second laminated block, and (B) is the second laminate in which the fifth to eighth reinforcing support members are joined. It is a perspective view of a block. (A) is a perspective view of a pair of light reflecting elements, and (B) is a perspective view of an optical imaging device in which light reflecting elements are joined in a state where the light reflecting layers are orthogonal to each other. It is a top view which tries to join a plurality of light reflecting elements side by side.

Subsequently, a method for manufacturing a light reflecting element used in the optical imaging device according to the first embodiment of the present invention will be described with reference to FIGS. 1 to 7. As shown in FIGS. 1 (A) and 1 (B), transparent glass which is an example of a rectangular transparent plate for finally manufacturing the light reflecting element 10 (see FIGS. 6 (A) and 6 (B)). A glass plate material 12a having a plate 11 and a light reflecting layer 12 provided on one surface of the glass plate 11 is used. The glass plate 11 forms, for example, a substantially square having a side of about 80 to 500 mm, but may be rectangular. The thickness of the glass plate 11 is, for example, 0.1 to 4.0 mm. The rectangular transparent plate may be formed of a transparent synthetic resin material (plastic) such as acrylic resin.

The glass plate 11 is flat on both sides and has a uniform thickness as much as possible. A light reflecting layer 12 is formed on the glass plate 11 by vapor deposition of a metal such as aluminum or silver. Instead of metal vapor deposition, the light reflecting layer 12 may be formed by a method such as sputtering, spraying, or plating. The thickness of the light reflecting layer 12 is preferably, for example, about 50 to 400 nm, but is not limited to this number. The light reflecting layer 12 may be formed on both sides of the glass plate 11.

A predetermined number (for example, 500 to 1000) of the glass plates 11 (that is, the glass plate material 12a) on which the light reflecting layer 12 is formed is prepared and the direction is orthogonal to the light reflecting layer 12 via the transparent first adhesive. Each glass plate material 12a is a flat surface such as a press before the first adhesive is hardened, and the surfaces A and B, and the surfaces C and D are pressed with sufficient pressing pressure. It is preferable that the first adhesive is uniformly stretched by being pressed to maintain the thickness h (distance between the surface A and the surface B) and the flatness and parallelism of the surface C and the surface D as much as possible (shown). As the first adhesive, it is preferable to use a self-hardening type or heat-curing type adhesive that cures with the passage of time (difficult-to-peelable type adhesive). The height h and the width w are determined (w> h). The height h is not changed, but w is reduced by polishing.

Here, the first and second support members 15 and 16 are pressed against the upper and lower surfaces A and B of the original laminated body 13 in the thickness direction via the second adhesive, and the surfaces A and B are referred to as the surfaces A and B. The third and fourth support members 17 and 18 are pressed against the opposing surfaces C and D of the orthogonal original laminate 13 via the second adhesive. Here, the width of the first and second support members 15 and 16 is made smaller than the width between the surfaces C and D of the original laminated body 13, and a gap is provided between the third and fourth support members 17 and 18. It is better to bring it in. Here, the second adhesive is an adhesive (usually called wax) that melts (liquefies) when heated (for example, heated to 80 ° C.) and solidifies firmly at room temperature, or a water-soluble adhesive. It is preferable to use an agent (above, a peelable adhesive).
The thickness h of the original laminated body 13 is set to be smaller than the width (inter-plane distance) w of the surfaces C and D by adjusting the number of glass plate materials 12a. As a result, the shape of the light reflecting element 10 which is the final product can be adjusted to a square shape with h = w (preferably within ± 0.1 mm, but not an essential requirement). The reason for this is that the width w between the surfaces C and D can be adjusted in a direction of decreasing in the polishing process. As a result, the first laminated block 19 shown in FIG. 2 is obtained (the above is the first step).

Next, the first laminated block 19 in which the joining (pressing and fixing) of the first to fourth support members 15 to 18 to the original laminated body 13 to which the glass plate material 12a is laminated and fixed is completed is attached to the first support member 15. It is fixed to a mounting table (not shown) with it facing up, and as shown in FIG. 2, a first laminated block is formed in a direction orthogonal to the light reflecting layer 12 of each glass plate material 12a from above the first supporting member 15. 19 is simultaneously cut (sliced) with a multi-wire saw 20 to a predetermined thickness (equally spaced) together with the first to fourth support members 15 to 18, and around as shown in FIGS. 3A and 3B. A plurality of light reflecting element raw materials 25 to which the cut pieces 21 to 24 of the first to fourth support members 15 to 18 are fixed are formed (the above is the second step).

After that, the light-reflecting element raw material 25 is made horizontal, and both sides of the light-reflecting element raw material 25 are optically polished (mirror-polished) with the surrounding cut pieces 21 to 24 fixed to the surface, preferably the arithmetic average roughness of the surface. Ra is set to about 1 to 0.1 μm or less (the same applies to the following polishing). In this case, since the cut pieces 21 to 24 of the support members 15 to 18 are fixed around the light reflecting element raw material 25, there is an advantage that the glass plate material 12a is not chipped or rolled up during cutting and polishing. There is. The thickness t of each light reflecting element raw material 25 is adjusted to be constant in consideration of the thickness at the time of cutting and the polishing allowance at the time of polishing (the above is the third step). In the figure, the four ▽ marks indicate that the polishing is ultra-precision optical polishing.

Next, as shown in FIG. 4A, the cut pieces 21 to 24 provided around the light reflecting element raw material 25 are heated or removed using a liquid (solvent) to remove the light reflecting element material 25a. , As shown in FIG. 4B, the second laminated block 27 is formed by laminating via a peelable third adhesive (same as the second adhesive) (the above is the fourth step). If the light reflecting element materials 25a are simply stacked, the flatness of the facing surfaces C'and D'of the second laminated block 27 is poor, so before the third adhesive hardens, a flat plate (not shown) is used. It is preferable to press the surface C'and the surface D'. As shown in FIG. 4B, the opposite surfaces C'and D'of the second laminated block 27 are optically polished in a state where the surfaces C'and D'are aligned to some extent. At this time, the distance w (width of the light reflecting element 10) between the optically polished surfaces C ″ and the surface D ″ is set to the thickness h of the original laminate 13 in the range of ± 0.5 mm, preferably in the range of ± 0.1 mm. It is better to match (the above is the fifth step).

After that, the bonding of the third adhesive is broken and the second laminated block 27 is decomposed into a plurality of light reflecting elements 10. The light reflecting element 10 has a thickness of t, and the shape viewed in a plane (viewing the cut surface in front) is a square having one side h (= w) (the above is the sixth step). Therefore, as shown in FIG. 6A, two light reflecting elements 10 are prepared, and the light reflecting layers 12 are arranged so as to be orthogonal to each other in a plan view, and a transparent fifth adhesive (first). The optical imaging apparatus 30 having a thickness of 2 tons is completed by joining with the same adhesive as the above. The optical imaging device 30 can form an image of an object arranged in one side space as a real image in the other side space.

In the above embodiment, the surfaces C'and D'are polished without providing a support member (protective member) around the second laminated block 27, but the surface C'and the surface D'are polished around the second laminated block 27 for reinforcement. When the support member of No. 5 is provided and polished, the chipping at the time of polishing disappears, and an embodiment in which this is prevented will be described with reference to FIGS. 5 (A) and 5 (B). That is, in the fourth step or between the fourth step and the fifth step, a plurality of light reflecting element materials 25a are placed on the fifth reinforcing support member 35 via a third adhesive that can be easily peeled off. It is laminated to form a second laminated block 27. The fifth to eighth surfaces (planes E to H) 31 to 34 surrounding the second laminated block 27 on the side surface orthogonal to the surface C'and the surface D'of the second laminated block 27 are the fifth to eighth. The reinforcing support members 35 to 38 of the above are attached via a peelable fourth adhesive (note that the fifth reinforcing support member 35 serves as a bottom plate). Here, the widths of the fifth and seventh reinforcing support members 35 and 37 are h (or shorter than h in a small range), and are sandwiched between the sixth and eighth reinforcing support members 36 and 38. It is preferable to keep it in a state. This prevents the second laminated block 27 from being scratched or curled during polishing.

Although the cut pieces 21 to 24 were removed in the third step, only the cut pieces 23 and 24 can be removed.
In the above-described embodiment, the rectangular transparent plate has been described using a glass plate, but a transparent resin or the like can also be used. Further, in the above-described embodiment, the light reflecting element is square in a plan view, but it may be rectangular.
Further, in the above-described embodiment, the light-reflecting layer is provided on each glass plate, but the light-reflecting layer may not be formed on the glass plate at the end.
Further, after the fourth step and before the fifth step, the ends of the surfaces E to H surrounding the second laminated block can be peeled off at right angles to the surfaces C'and D'of the second laminated block. The surface C'and the surface D'may be polished in the fifth step by reinforcing with a fourth adhesive (for example, wax). As a result, the side surface of the second laminated block is further reinforced and there is no chipping during polishing.

In FIG. 7, a plurality of light reflecting elements 10 manufactured by the above steps (in this embodiment, four, further 9, 16, or any other number), and the orientation of the light reflecting layer 12 are aligned. The large-sized light reflecting elements 40 joined side by side horizontally are shown by two positioning members 43, 44 and pressing members 45, 46 mounted on a transparent flat base 41 and arranged at right angles. It is held in place. In this case, since the shapes of the light reflecting elements 10 are the same, the positions of the light reflecting layers 12 of the adjacent light reflecting elements 10 can be aligned, and a larger optical imaging device can be manufactured.

10: Light reflecting element, 11: Glass plate, 12: Light reflecting layer, 12a: Glass plate material, 13: Original laminate, 15: First support member, 16: Second support member, 17: Third support Member, 18: 4th support member, 19: 1st laminated block, 20: wire saw, 21-24: cut piece, 25: light reflecting element raw material, 25a: light reflecting element material, 27: second Laminated block, 30: Optical imaging device, 31 to 34: 5th to 8th planes, 35 to 38: 5th to 8th reinforcing support members, 40: Large light reflecting element, 41: Planar base Table, 43, 44: Positioning member, 45, 46: Pressing member

Claims (4)

A method for manufacturing a light reflecting element used in an optical imaging device that forms an image of an object arranged in one side space as a real image in the other side space.
A plurality of rectangular transparent plates having a light-reflecting layer formed on at least one surface thereof are laminated and fixed via a first adhesive in a direction orthogonal to the light-reflecting layer to form an original laminate. The first to fourth support members are pressed against the upper and lower surfaces A and B in the thickness direction of the original laminated body, and the surfaces C and D facing orthogonal to the surfaces C and D, respectively, via a second adhesive that can be peeled off. The first step of forming the fixed first laminated block and
A second step of cutting the first laminated block together with the first to fourth support members at equal intervals in a direction orthogonal to the light reflecting layer to manufacture a light reflecting element raw material.
The third step of polishing the cut surface of the cut light reflecting element raw material in a state where the cut pieces of the first to fourth support members are fixed, and the third step.
A plurality of light reflecting element materials polished in the third step and from which the cut pieces of the first to fourth support members have been removed are stacked and fixed with a peelable third adhesive to form a second laminated block. The fourth step of forming and
The fifth step of polishing the facing surfaces C'and D'of the second laminated block to adjust the width of the light reflecting element material to a specified value.
A method for manufacturing a light-reflecting element, which comprises a sixth step of melting the third adhesive to form the light-reflecting element. In the method for manufacturing a light reflecting element according to claim 1, a fourth adhesive that can be peeled off from a surface E to a surface H that is orthogonal to the surface C'and the surface D'before the fifth step is used. A method for manufacturing a light reflecting element, which comprises joining the fifth to eighth reinforcing support members to prevent the occurrence of defects in the second laminated block. In the method for manufacturing a light reflecting element according to claim 2, the facing 6th and 8th reinforcing support members surrounding the 2nd laminated block are opposed to the 5th and 7th reinforcing support members. A method for manufacturing a light-reflecting element, which is characterized by sandwiching the light-reflecting element. In the method for manufacturing a light reflecting element according to any one of claims 1 to 3, where h is the thickness of the original laminated body, the width of the light reflecting element obtained from the polished second laminated block. A method for manufacturing a light reflecting element, wherein w is in the range of h ± 0.5 mm and the shape of the light reflecting element in a plan view is a square.

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