JP4655659B2 - Optical element manufacturing method - Google Patents

Description

  The present invention relates to a method for manufacturing an optical element, and more particularly to a method for manufacturing a prism-shaped optical element having an inclined reflecting surface.

  Conventionally, as an optical element, as shown in FIG. 5, a prism-like mirror 1 having a light reflecting film on an inclined surface 1a is used. This type of mirror 1 is incorporated in, for example, a recording / reproducing optical pickup of a recording disk 9. Of the light beam emitted from the light source 5, a predetermined polarization component transmitted through the polarization separation film 6 a of the beam splitter 6 is reflected by the light reflection film and guided to the disk 9 through the lens 7. The reflected light from the disk 9 travels in the opposite direction with the polarization plane rotated, reflected by the polarization separation film 6a, and detected by the light receiving element 8.

  As shown in FIG. 6, in the prior art, the mirror 1 having a prism shape is made of a long mirror connecting body 1 'having an inclined surface 1a made of a glass material, and is formed on the inclined surface 1a of the connecting body 1'. In addition to forming a light reflecting film, the light reflecting film was cut into a predetermined size as indicated by the alternate long and short dash line and separated into individual mirrors. However, since this manufacturing method manufactures each long mirror coupling body one by one, it is not efficient, and a manufacturing method capable of obtaining a larger number of pieces is required.

  On the other hand, Patent Document 1 discloses that a polarizing beam splitter is manufactured through the following steps.

(A) preparing a plurality of flat optical members, forming a polarization separation film on one surface, and forming a matching film on the other surface;
(B) a step of laminating the optical member in a stepped manner with an adhesive at an inclination angle of 45 ° to form a laminate;
(C) a step of cutting the laminated body bonded and integrated into a plurality of laminated division bodies at a plurality of parallel cut surfaces having a predetermined pitch along a 45 ° inclination angle;
(D) Mirror-finishing both surfaces of each of the laminated divided bodies, and forming an antireflection film on the processed surface;
(E) a step of laminating a plurality of laminated division bodies formed with an antireflection film in an aligned state, and temporarily fixing each laminated division body with paraffin;
(F) a step of cutting the plurality of temporarily laminated laminated bodies along a cut surface perpendicular to the cut surface to form a temporarily fixed laminate;
(G) Mirror-finishing both surfaces of the cut surface of the temporary fixing laminate, and forming an antireflection film on the processed surface;
(H) a step of cutting the temporary fixing laminated body at a predetermined interval in a direction perpendicular to the cut surface to form a plurality of beam splitter coupled bodies;
(I) A step of heating the beam splitter connected body to dissolve and remove paraffin to separate the beam splitter into individual beam splitters.

The manufacturing process suggests a technical idea of laminating flat optical members and repeatedly cutting, re-laminating, and cutting to obtain a large number of individual beam splitters, but it does not consider even the production of mirrors. .
JP 2000-143264 A

  Therefore, an object of the present invention is to provide a manufacturing method capable of efficiently manufacturing a prism-like optical element having an inclined reflecting surface.

In order to achieve the above object, a method for manufacturing an optical element according to the first invention includes:
(A) preparing a parallel plate composed of a plurality of transparent media;
(B) a step of temporarily adhering the parallel plates with a first adhesive to form a laminate;
(C) cutting the laminated body into a plurality of laminated division bodies along a plurality of parallel first cutting directions at a predetermined pitch along a predetermined inclination angle;
(D) a step of laminating the cut surfaces of the laminated divided body facing each other, and temporarily bonding with a second adhesive;
(E) a step of cutting the plurality of temporarily bonded laminated division bodies into a plurality of temporarily bonded flat plates along a second cutting direction perpendicular to the laminated surface;
(F) dissolving the first and second adhesives to form a long optical element connector from the temporary adhesive flat plate;
(G) cutting the optical element connector into a predetermined size and separating the optical element connector into individual optical elements ,
(H) In the step of cutting into a plurality of temporarily bonded flat plates along the second cutting direction, cutting at a position not including the temporary bonded surface of the parallel plate and a position including the temporary bonded surface;
It is characterized by.

  In the manufacturing method according to the first aspect of the present invention, a laminated body in which parallel flat plates made of a plurality of transparent media are temporarily bonded is formed, cut into a plurality of laminated division bodies in the first cutting step, and then further laminated. The body is temporarily bonded, cut into a plurality of temporarily bonded flat plates in the second cutting step, and the first and second adhesives are dissolved to obtain a long optical element linked body. That is, in the series of steps, it is possible to efficiently obtain a long optical element connected body immediately before being separated into individual optical elements (mirrors), and, in turn, a prism-like optical element having an inclined reflecting surface. It can be manufactured efficiently.

The manufacturing method of the optical element according to the second invention is as follows:
(A) preparing a first parallel flat plate made of a plurality of transparent media having a first thickness and a plurality of second parallel flat plates having a second thickness smaller than the first thickness;
(B) temporarily bonding the first and second parallel flat plates with a first adhesive to form a laminate;
(C) cutting the laminated body into a plurality of laminated division bodies along a plurality of parallel first cutting directions at a predetermined pitch along a predetermined inclination angle;
(D) a step of laminating the cut surfaces of the laminated divided body facing each other, and temporarily bonding with a second adhesive;
(E) cutting the temporarily laminated plurality of laminated division bodies into a plurality of temporarily bonded flat plates along a second cutting direction perpendicular to the laminated surface;
(F) dissolving the first and second adhesives to form a long optical element connector from the temporary adhesive flat plate;
(G) cutting the optical element connector into a predetermined size and separating the optical element connector into individual optical elements,
(H) In the step of cutting into a plurality of temporarily bonded flat plates along the second cutting direction, a position not including the temporary bonded surfaces of the first and second parallel flat plates and a position including the temporary bonded surfaces. Cutting,
It is characterized by.

  Also in the manufacturing method according to the second invention, as in the manufacturing method according to the first invention, it is possible to efficiently obtain a long optical element assembly immediately before being separated into individual optical elements (mirrors). Of course, it is possible to manufacture a prism-like optical element having a shape obtained by cutting off the tip corner portion of the inclined reflecting surface with less material waste.

In the above manufacturing method according to the first invention, it may be light reflecting film is deposited on the surface of the hand of the parallel plate. In the manufacturing method according to the second aspect of the present invention, the light reflecting film may be formed on both surfaces or one surface of the first parallel plate. Alternatively, the manufacturing method according to the first and second inventions may further include a step of forming a light reflecting film on the slant surface of the elongated optical element connector or the optical elements separated individually. .

  In the first and second manufacturing methods, a photocurable adhesive may be used as the first and second adhesives, and the adhesives may be temporarily cured.

  Furthermore, after cutting the laminated body into a plurality of laminated divided bodies, polishing both surfaces of the cut surface of the laminated divided body, and cutting the laminated divided bodies into a plurality of temporarily bonded flat plates, Polishing both surfaces of the cut surface. It is possible to obtain a mirror that is used in a form in which light is transmitted through the element and reflected.

  Embodiments of an optical element manufacturing method according to the present invention will be described below with reference to the accompanying drawings.

(See the first embodiment, FIG. 1)
The first embodiment is for manufacturing the mirror 1 incorporated in the optical pickup shown in FIG. 5, and is manufactured in the order of steps (A) to (G) shown in FIG. As shown in FIG. 4A, the mirror 1 is a quadrangular prism having an inclined surface 1a having a rectangular parallelepiped cut out and having a trapezoidal vertical section. More specifically, the prism is a quadrangular prism having a trapezoidal quadrangular vertical section and three adjacent vertical surfaces 1b, 1c, 1d and an inclined surface 1a having an angle θ.

  First, in step (A), a plurality of glass parallel plates 10 are prepared, and light reflecting films are formed on both surfaces of the parallel plates 10. The light reflection film is, for example, a metal film such as aluminum or silver, a dielectric multilayer film, or a film in which a metal film and a dielectric film are laminated, and is formed by vapor deposition or sputtering, for example.

  In the step (B), the laminated body 11 is formed by temporarily adhering the parallel plate 10 to a predetermined inclination angle θ (for example, 45 °) with the first adhesive. In this case, if the jig 20 having the inclined surface 21 with the angle θ is used, the workability is good. As the first adhesive, a material having a property of being dissolved in a solvent is used. For example, the laminate 11 is temporarily bonded by temporarily curing a soluble ultraviolet curable adhesive.

  As the solvent for the ultraviolet curable adhesive, for example, a hydrocarbon-based cleaning agent is used. The release agent (solvent) for dissolving the temporary adhesive is different depending on the type of adhesive used, and depending on the type of adhesive, water-based release agent, high-temperature (for example, 80 ° C. or higher) water, or organic solvent Etc. can be used.

  In the step (B), it is not always necessary to temporarily bond the parallel flat plate 10 in a state where the parallel plate 10 is shifted to the predetermined inclination angle θ. However, in consideration of cutting in the next step (C), the parallel plate 10 is shifted to the inclination angle θ. This is advantageous in that there is no waste of material.

  Next, in the step (C), the laminated body 11 is divided into a plurality of laminated divided bodies 12 (C ′) along a plurality of parallel first cutting directions (refer to the alternate long and short dash line a) at a predetermined pitch along the inclination angle θ. To see).

  In the step (D), the cut surfaces of the laminated divided bodies 12 are laminated so as to face each other, and temporarily bonded with a second adhesive. As the second adhesive, a material having a property of being dissolved in a solvent is used. For example, the laminated divided body 12 is temporarily bonded by temporarily curing a soluble ultraviolet curable adhesive.

  Next, in the step (E), a plurality of temporarily bonded flat plates 12 are bonded along the second cutting direction (see the alternate long and short dash line b) perpendicular to the stacked surface of the plurality of laminated division bodies 12 temporarily bonded in the step (D). 13 (see E ').

  In the step (F), the temporary bonding flat plate 13 is immersed in a solvent to dissolve the first and second adhesives, and the long mirror connector 14 is obtained.

  Next, in a process (G), the mirror coupling body 14 is cut | disconnected to a predetermined dimension, and is isolate | separated into each mirror 1. FIG.

  Through the above steps (A) to (G), the prism-like mirror 1 having a light reflecting film on the inclined surface 1a is obtained. In this manufacturing method, it is possible to efficiently obtain the long coupled body 14 immediately before being separated into the individual mirrors 1 in a state where a light reflecting film is formed on the inclined surface 1a.

  In particular, in the step (E), when the laminated divided body 12 is cut into a plurality of temporary adhesion flat plates 13 along a second cutting direction perpendicular to the lamination surface, the temporary adhesion surfaces (light reflecting films) of the parallel flat plates 10. Since the temporary bonding surface is cut at an intermediate position that is not included in the cut surface, the mirror 1 having the same shape is efficiently manufactured.

  Moreover, when cut into a plurality of laminated division bodies 12 in the step (C), both surfaces of the cut surface of the laminated division body 12 are polished, and further cut into a plurality of temporary adhesive flat plates 13 in the step (E). The both surfaces of the cut surface of the temporary bonding flat plate 13 may be polished. The polishing here is, for example, lapping polishing. By performing such polishing, it is possible to use the obtained light reflecting film of the mirror 1 as an inner surface reflecting film.

(See the second embodiment, FIG. 2)
In the second embodiment, steps (A) to (D) are the same as those in the first embodiment (however, a light reflection film is formed on one surface of the parallel plate 10), and is shown in FIG. Thus, at a process (E), the laminated division body 12 is cut | disconnected to temporary adhesion flat plates 13 and 13 '(refer E') along the cutting lines b1 and b2. Here, the position (cutting line b1) where the cut surface does not include the temporary bonding surface (light reflecting film) of the parallel plate 10 and the position (cutting line) including the temporary bonding surface (light reflecting film) of the parallel plate 10 on the cutting surface. and b2) are cut at a predetermined pitch. The subsequent steps (F) and (G) are the same as in the first embodiment. The temporary bonding flat plate 13 ′ is discarded.

  In the second embodiment, it is possible to efficiently manufacture the prism-like mirror 1 having a shape obtained by cutting off the tip corner 1a 'of the inclined surface 1a provided with the light reflecting film. As shown in FIG. 4B, the mirror 1 is a prism having an inclined surface 1a obtained by cutting off a corner of a rectangular parallelepiped and having a pentagonal cross section. More specifically, the prism is a pentagonal prism having a pentagonal vertical cross section and four vertical surfaces 1b, 1c, 1d, and 1a 'adjacent to each other and an inclined surface 1a that forms an angle θ.

(Refer to the third embodiment, FIG. 3)
In the third embodiment, a large number of mirrors 1 having a shape obtained by cutting off the tip corner portion 1a ′ manufactured in the second embodiment can be efficiently taken with less waste of material.

  Although not shown in FIG. 3, first, in the step (A), a first glass parallel plate having a relatively large thickness and a second thin parallel plate having a relatively small thickness are prepared, and both sides of the first parallel plate are prepared. A light reflecting film is formed. Next, in the step (B), the first and second parallel flat plates are temporarily bonded with a first adhesive that is soluble in a solvent while being shifted to a predetermined inclination angle θ (for example, 45 °, see FIG. 1). To form a laminate.

  Thereafter, as shown in FIG. 3, in the step (C), the stacked body 11 is stacked at a predetermined pitch along the inclination angle θ along a plurality of parallel first cutting directions (see the alternate long and short dash line a). Cut into divided bodies 12 (see C ′). In FIG. 3C, 10A indicates a first parallel plate, and 10B indicates a second parallel plate.

  In the step (D), the cut surfaces of the laminated divided bodies 12 are laminated so as to face each other, and temporarily bonded with the second adhesive described in the first embodiment.

  Next, in the step (E), the plurality of laminated divided bodies 12 temporarily bonded in the step (D) are arranged in a plurality of temporary portions along a second cutting direction (see the alternate long and short dash lines b1 and b2) perpendicular to the laminated surface. Cut into adhesive plates 13, 13 '(see E'). Here, the intermediate position (cutting line b1) of the temporary bonding surface that does not include the temporary bonding surface (light reflecting film) between the first parallel flat plate 10A and the second parallel flat plate 10B on the cutting surface, and the first on the cutting surface. The position (cut line b2) including the temporary adhesion surface (light reflecting film) between the parallel plate 10A and the second parallel plate 10B is cut at a predetermined pitch. The laminated divided body 12 is cut in the middle between the light reflecting films by the cutting line b1, and the tip corner 1a '(see FIG. 3G) of the inclined surface 1a provided with the light reflecting film is cut by the cutting line b2.

  In the step (F), the temporary bonding flat plate 13 is immersed in a solvent to dissolve the first and second adhesives, and the long mirror connector 14 is obtained.

  Next, in a process (G), the mirror coupling body 14 is cut | disconnected to a predetermined dimension, and is isolate | separated into each mirror 1. FIG.

  In the third embodiment, it is possible to efficiently obtain the prism-like mirror 1 having the light reflection film on the inclined surface 1a and having the tip corner portion 1a 'cut off, and in addition, the second embodiment. This has the advantage that less material is wasted.

  In the third embodiment, similarly to the first embodiment, when cutting into a plurality of laminated division bodies 12 in the step (C), both surfaces of the cut surfaces of the laminated division bodies 12 are polished, When cutting into a plurality of temporary bonded flat plates 13 in step (E), a step of polishing both surfaces of the cut surfaces of the temporary bonded flat plates 13 may be added.

(Other examples)
In addition, the manufacturing method of the optical element which concerns on this invention is not limited to the said Example, It can change variously within the range of the summary.

  For example, in the first, second and third embodiments, an optical element having a light reflecting film is manufactured by laminating parallel plates having a light reflecting film, but the light reflecting film is formed. The parallel reflection flat plate may be laminated and a light reflecting film may be formed on the obtained long element coupling body or the inclined surface of the individually separated optical element.

  In addition to the ultraviolet curable adhesive, a visible light curable adhesive, a thermosetting adhesive, or the like can be used as the adhesive.

It is explanatory drawing which shows 1st Example of the manufacturing method of the optical element which concerns on this invention. It is explanatory drawing which shows the principal part of 2nd Example of the manufacturing method of the optical element which concerns on this invention. It is explanatory drawing which shows the principal part of 3rd Example of the manufacturing method of the optical element which concerns on this invention. (A) is a perspective view of the optical element manufactured by 1st Example, (B) is a perspective view of the optical element manufactured by 2nd and 3rd Example. It is a schematic explanatory drawing which shows the optical pick-up using a mirror. It is a perspective view which shows the conventional mirror manufacturing method.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Mirror 1a ... Inclined surface 10, 10A, 10B ... Parallel plate made of glass 11 ... Laminated body 12 ... Laminated division body 13 ... Temporary adhesion flat plate 14 ... Mirror coupling body

Claims (7)

Preparing a parallel plate made of a plurality of transparent media;
Temporarily bonding the parallel plates with a first adhesive to form a laminate;
Cutting the laminated body into a plurality of laminated divided bodies along a plurality of parallel first cutting directions at a predetermined pitch along a predetermined inclination angle;
Laminating the cut surfaces of the laminate divided body facing each other, temporarily bonding with a second adhesive,
Cutting the plurality of temporarily divided laminated pieces into a plurality of temporarily bonded flat plates along a second cutting direction perpendicular to the laminated surface;
Dissolving the first and second adhesives to form a long optical element connector from the temporary adhesive flat plate;
Cutting the optical element coupling body into predetermined dimensions and separating them into individual optical elements;
Equipped with a,
In the step of cutting into a plurality of temporarily bonded flat plates along the second cutting direction, cutting at a position not including the temporary bonded surface of the parallel plate and a position including the temporary bonded surface;
A method for producing an optical element characterized by the above. 2. The method of manufacturing an optical element according to claim 1 , wherein a light reflection film is formed on one surface of the parallel plate. Preparing a first parallel plate made of a plurality of transparent media having a first thickness, and a plurality of second parallel plates having a second thickness smaller than the first thickness;
Temporarily bonding the first and second parallel flat plates with a first adhesive to form a laminate;
Cutting the laminated body into a plurality of laminated divided bodies along a plurality of parallel first cutting directions at a predetermined pitch along a predetermined inclination angle;
Laminating the cut surfaces of the laminate divided body facing each other, temporarily bonding with a second adhesive,
Cutting the plurality of temporarily divided laminated pieces into a plurality of temporarily bonded flat plates along a second cutting direction perpendicular to the laminated surface;
Dissolving the first and second adhesives to form a long optical element connector from the temporary adhesive flat plate;
Cutting the optical element coupling body into predetermined dimensions and separating them into individual optical elements, and
In the step of cutting into a plurality of temporarily bonded flat plates along the second cutting direction, cutting at a position not including the temporary bonded surfaces of the first and second parallel flat plates and a position including the temporary bonded surfaces. ,
A method for producing an optical element characterized by the above. 4. The method of manufacturing an optical element according to claim 3 , wherein a light reflecting film is formed on both surfaces or one surface of the first parallel plate. Further, according to claim 1 or claim 3, characterized in that it comprises a step of forming a light reflecting film on the inclined surface of said elongated optical element connecting body or the individually separated optical element A method for manufacturing an optical element. It said first and using light curing adhesive as the second adhesive, method of manufacturing an optical element according to any one of claims 1 to 5, characterized in that temporarily curing the adhesive. After cutting the laminated body into a plurality of laminated divided bodies, polishing both surfaces of the cut surface of the laminated divided bodies;
After cutting the laminated divided body into a plurality of temporarily bonded flat plates, polishing both surfaces of the cut surface of the temporarily bonded flat plate,
The method for manufacturing an optical element according to any one of claims 1 to 6, characterized in that with a.

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