JP5491651B2 - 封入光学素子を提供するための光デバイスの連結方法 - Google Patents
封入光学素子を提供するための光デバイスの連結方法 Download PDFInfo
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- JP5491651B2 JP5491651B2 JP2013050401A JP2013050401A JP5491651B2 JP 5491651 B2 JP5491651 B2 JP 5491651B2 JP 2013050401 A JP2013050401 A JP 2013050401A JP 2013050401 A JP2013050401 A JP 2013050401A JP 5491651 B2 JP5491651 B2 JP 5491651B2
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- G03F7/2053—Exposure without an original mask, e.g. using a programmed deflection of a point source, by scanning, by drawing with a light beam, using an addressed light or corpuscular source using a laser
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- G03H—HOLOGRAPHIC PROCESSES OR APPARATUS
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- G03H1/04—Processes or apparatus for producing holograms
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Description
この出願は、2000年6月15日に出願された米国仮出願第60/211,709号(その全内容を本願明細書に引用したものとする)の優先権を主張する。
第一に、本願発明は、
第1の光デバイスを第2の光デバイスに連結する方法であって、
(a)光硬化性官能価を含む成分中に少なくとも部分的に封入された、部分的に形成された第1の光学素子を備える第1の光デバイスを提供する工程であって、前記部分的に形成された第1の光学素子が、光硬化性材料を含む領域によって前記第1の光デバイスの境界から隔置されている端部を有する、工程と、
(b)前記第1の光学素子の前記端部が、第2の光デバイスに組み込まれた第2の光学素子の端部と整列して少なくとも略並置されるように、前記第1の光デバイスを前記第2の光デバイスに隣接して配置し、光硬化性材料を含有する領域が前記端部の間に配置される工程と、
(c)前記第1及び第2の光学素子の前記端部が相互に光学的に連結される条件下で前記領域の少なくとも一部分を光硬化する工程と、を含む方法に関する。
第二に、本願発明は、
第1の光デバイスを第2の光デバイスに連結する方法であって、
(a)結合剤、光硬化性母材前駆物質、及び多光子光開始剤系を含む成分中に少なくとも部分的に封入された、部分的に形成された第1の光学素子を備える第1の光学素子デバイスを提供する工程であって、前記部分的に形成された光学素子が、本体の境界から隔置されている端部を有し、多光子光硬化性領域が前記端部と前記境界との間に並置される工程と、
(b)前記第1の光学素子に連結される端部を有する第2の光学素子を備える第2の光学素子デバイスを提供する工程と、
(c)前記第1の光学素子デバイスを前記第2の光学素子デバイスに隣接して配置して、前記第1及び第2の光学素子の前記端部を互いに整列して少なくとも略並置し、前記多光子光硬化性領域が前記端部の間に配置される工程と、
(d)前記第1及び第2の光学素子の前記端部が相互に光学的に連結される条件下で前記領域の少なくとも一部分を光硬化する工程と、を含む方法に関する。
本発明は、高度の精度を有する3次元の、安定した光学素子の加工方法を提供する。画像の通りの多光子重合(multiphoton polymerization)及びブランケット照射技術を組み合わせて、封入保護モノリシック高分子母材中でかかる光学素子をin situ加工する。画像の通りの多光子重合技術を用いて、多光子重合性物質を混入する本体中に光学素子を形成する。光学素子を囲む本体はまた、ブランケット照射及び/または熱硬化によって光硬化されて、封入構造体を形成するのを助ける。最終成果は、良好な分解能、硬度、耐久性、寸法安定性、レジリエンス、屈折率の対比、及び靭性を有する封入構造体である。
(i)光重合した時にポリマー母材を形成し、前記母材が屈折率を有する、拡散種を含む光重合性前駆物質と、
(ii)前記ポリマー母材の前記屈折率より低い屈折率を有すると共に前記光重合性前駆物質と混和性である実質的に非拡散性の結合剤成分と、
(iii)多光子光開始剤系と、を含有する本体が提供される。前記本体の少なくとも一部分が、3次元光学素子を形成するために有効なパターンで前記ポリマー前駆物質を多光子光重合するのに有効な条件下で多光子重合誘導エネルギー(multiphoton polymerizing fluence of energy)に画像の通り露光される。前記本体を画像の通り露光した後に、モノリシック封入母材が前記光学素子の少なくとも一部分の周りに形成される条件下で、前記本体の少なくとも一部分が、例えば、ブランケット照射によって、光重合誘導エネルギーに画像の通りではなく露光される。
(a)光硬化性官能価を含む成分中に少なくとも部分的に封入された、部分的に形成された第1の光学素子を備える第1の光デバイスを提供する工程であって、前記部分的に形成された第1の光学素子が、光硬化性材料を含む領域によって前記第1の光デバイスの境界から隔置されている端部を有する、工程と、
(b)前記第1の光学素子の前記端部が、第2の光デバイスに組み込まれた第2の光学素子の端部と整列して少なくとも略並置されるように、前記第1の光デバイスを前記第2の光デバイスに隣接して配置し、光硬化性材料を含有する領域が前記端部の間に配置される工程と、
(c)前記第1及び第2の光学素子の前記端部が相互に光学的に連結される条件下で前記領域の少なくとも一部分を光硬化する工程と、を含む方法、に関する。
(a)結合剤、光硬化性母材前駆物質、及び多光子光開始剤系を含む成分中に少なくとも部分的に封入された、部分的に形成された第1の光学素子を備える第1の光学素子デバイスを提供する工程であって、前記部分的に形成された光学素子が、本体の境界から隔置されている端部を有し、多光子光硬化性領域が前記端部と前記境界との間に並置される工程と、
(b)前記第1の光学素子に連結される端部を有する第2の光学素子を備える第2の光学素子デバイスを提供する工程と、
(c)前記第1の光学素子デバイスを前記第2の光学素子デバイスに隣接して配置して、前記第1及び第2の光学素子の前記端部を互いに整列して少なくとも略並置し、前記多光子光硬化性領域が前記端部の間に配置される工程と、
(d)前記第1及び第2の光学素子の前記端部が相互に光学的に連結される条件下で前記領域の少なくとも一部分を光硬化する工程と、を含む方法、に関する。
以下に記載した本発明の実施態様は網羅的であること、または以下の詳細な説明に開示された正確な形に本発明を制限することを意図するものではない。むしろ実施態様は、当業者が本発明の原理及び実施を正当に評価し、理解するように選択及び記載される。
40重量%のポリメチルメタクリレート(mw120,000、n=1.490、ウィスコンシン州、ミルウォーキーのアルドリッチケミカルカンパニー製)、25重量%のフェノキシエチルアクリレート、34重量%のビスフェノールAグリセロレートジアクリレート(ジョージア州、シマーナのUCBケミカル製のEbecryl 3700TM)、及び1重量%の4,4’−ビス(ジフェニルアミノ)−trans−スチルベンを含有する溶液(メチレンクロリド中に固形分40%)を調製する。溶液を厚さ約500ミクロンのシリコンウエハ上に被覆し、60℃のオーブン内で乾燥させる。露光を、4,4’−ビス(ジフェニルアミノ)−trans−スチルベンの2光子吸収最大値、700nmを作動するTiサファイヤレーザーを有する2光子顕微鏡を用いて行ない、光を、NA=1.4の油浸レンズを通して集束させる。試料のXYZ制御を、顕微鏡試料台上に取付けたマニピュレータを用いて実施する。薄膜の平面に平行な及び垂直な一次軸を有する相互接続した導波管のパターンが、媒体中に書き込まれ、前記パターンの3次元画像をもたらし、そこにおいて、硬化導波管の屈折率の変調(modulation)は、引き続いて硬化された母材に対して少なくとも0.01である。次に、被覆を、10分間、350nmで一次出力を有する6つのシルバニアF15T8/350BLバルブ(マサチューセッツ州、ダンバーのオスラムシルバニア社製)のバンクを用いて画像の通りではなくブランケット露光する。前記薄膜は、導波管に対して少なくとも0.01の屈折率の変調を維持し、前記導波管は、導入された光を有効に搬送することができる。
60重量%のセルロースアセテートブチレート(MW70,000、13.5重量%のアセチル、37重量%のブチリル、ウィスコンシン州、ミルウォーキーのアルドリッチケミカルカンパニー製)、25重量%のフェノキシエチルアクリレート、34重量%のビスフェノールAグリセロレートジアクリレート(ジョージア州、シマーナのUCBケミカル製のEbecryl 3700TM)、及び1重量%の4,4’−ビス(ジフェニルアミノ)−trans−スチルベンを含有する溶液(メチレンクロリド中に固形分40%)を調製する。溶液を厚さ約500ミクロンのシリコンウエハ上に被覆し、60℃のオーブン内で乾燥させる。露光を、4,4’−ビス(ジフェニルアミノ)−trans−スチルベンの2光子吸収最大値、700nmを作動するTiサファイヤレーザーを有する2光子顕微鏡を用いて行ない、光を、NA=1.4の油浸レンズを通して集束させる。試料のXYZ制御を、顕微鏡試料台上に取付けたマニピュレータを用いて実施する。薄膜の平面に平行な及び垂直な一次軸を有する相互接続した導波管のパターンが、媒体中に書き込まれ、前記パターンの3次元画像をもたらし、そこにおいて、硬化導波管の屈折率の変調(modulation)は、少なくとも0.01である。次に、被覆を、10分間、350nmで一次出力を有する6つのシルバニアF15T8/350BLバルブ(オスラムシルバニア社製)のバンクを用いて画像の通りではなくブランケット露光する。前記薄膜は、導波管に対して少なくとも0.01の屈折率の変調を維持し、前記導波管は、導入された光を有効に搬送することができる。
特に指示しない限り、実施例3〜5で用いた化学物質は、ウィスコンシン州、ミルウォーキーのアルドリッチケミカルカンパニー製であった。CGI 7460は、ニューヨーク州、タリータウンのチバスペシャルティケミカルズ製のボラート塩であり、CD1012はペンシルベニア州、ウェストチェスターのサートマーカンパニー製であるジアリールヨードニウムヘキサフルオロアンチモネート塩である。2000年12月21日に出願された、譲受人の係属中の出願第09/746,613号(代理人整理番号55983USA7A)の13ページの実施例1の前に記載された手順に従って、材料2−(1−ナフトキシ)エチルアクリレートを作製した。
ガラスと活性層との間の低屈折率緩衝層を作製するために、顕微鏡スライド上に表1に示した組成物の溶液(1,2−ジクロロエタン中に固形分16%)をスピン被覆し、10分間、80℃のオーブン内で溶剤を蒸発させ、次に、シルバニア350BLB UV光下で10分間、硬化させた。硬化緩衝層の厚さは、約10ミクロンであった。
この実施例において、試料によって受容された硬化エネルギーの線量を、屈折率の対比を制御するために変化させた。表1及び2に記載されているのと同じ組成物の試料を、60X顕微鏡対物レンズ(空中のN.A.は0.85である)及び106mWの平均電力を用いて露光した。ビームの焦点が硬化性層のだいたい真中にあるように、試料を配置した。50マイクロメータ/秒〜51.2mm/秒の速度で集束ビーム下で試料を走査することによって、導波管を作った。次に、被覆を45分間、3つのフィリップスTLD 15W−03バルブのバンクを用いて画像の通りではなくブランケット露光した。各々の導波管の屈折率を、白色光でイエナ干渉顕微鏡上でMach Zehnder干渉法を用いて確認した。バルク薄膜の屈折率をイエナ干渉計を用いて確認すると、1.49であった。データは、導波管における屈折率の対比は、−4.5(log線量、J/マイクロメータ)で約0.002対−2.8(log線量、J/マイクロメータ)で約0.063の対比から実質的に線的に増大線量のlogによって増大した。線量は、平均電力を線走査速度で割って求められ、1ミクロン当たりのジュールの単位を有する。このエネルギー範囲にわたって、試料の損傷の形跡はなかった。
この実施例において、導波管及びY−スプリッタを説明する。表1及び2に記載したのと同じ組成物の試料を調製し、40X顕微鏡対物レンズ(空気中のN.A.は0.65である)及び60mWの平均電力を用いて露光した。10cmの焦点距離の視野レンズを、ビームを拡大して顕微鏡対物レンズの全口径を占めるために光学縦列内に置いた。Y−スプリッタは、同じパターンで20mm/秒で5回通過することによって書き込まれた。光学マイクログラフを用いて、上部から及び断面で見られたスプリッタを観察した。スプリッタを材料のバルク中に確かに封入し、各アームの側方厚さは約2マイクロメータであった。断面において、構造体は、上から順に、ガラス層、処理組成物の層、エポキシ層、及び別のガラス層を備えた。断面の画像のために、ガラススライドを、実施例3に記載したように上面に接着し、試料をさいの目状に切って導波管の端部を露光した。
本願発明に関連する発明の実施形態を以下に列挙する。
[実施形態1]封入光学素子の加工方法であって、
(a)(i)光重合した時にポリマー母材を形成し、硬化した母材が屈折率を有する、拡散種を含む光重合性前駆物質と、
(ii)前記硬化した母材の前記屈折率より低い屈折率を有すると共に前記光重合性前駆物質と混和性である実質的に非拡散性の結合剤成分と、
(iii)多光子光開始剤系と、を含む本体を提供する工程と、
(b)3次元光学素子を形成するために有効なパターンでポリマー前駆物質を多光子光重合するのに有効な条件下で前記本体の少なくとも一部分をエネルギーに画像の通り露光する工程と、
(c)前記本体を画像の通り露光した後に、前記本体の少なくとも一部分を光重合誘導エネルギーに画像の通りではなく露光する工程と、を含む、方法。
[実施形態2]前記結合剤が、熱可塑性ポリマーを含む成分から誘導される、実施形態1に記載の方法。
[実施形態3]前記結合剤が、光硬化性官能価を実質的に有しない熱硬化性ポリマーを含む成分から誘導される、実施形態1に記載の方法。
[実施形態4]前記多光子光開始剤系が多光子光増感剤を含む、実施形態1に記載の方法。
[実施形態5]前記多光子光開始剤系が単一光子光開始剤を更に含む、実施形態4に記載の方法。
[実施形態6]前記多光子光開始剤系が電子供与体を更に含む、実施形態5に記載の方法。
[実施形態7]ブランケット照射工程が単一光子重合を引き起こすことを含む、実施形態1に記載の方法。
[実施形態8]前記ブランケット照射工程が多光子重合を引き起こすことを含む、実施形態1に記載の方法。
[実施形態9]前記画像の通り露光する工程が、低減された量の前記拡散種を含む空乏領域を前記光学素子の境界に形成させることを含む、実施形態1に記載の方法。
[実施形態10]前記画像の通り露光する工程が複数のフェムト秒レーザーパルスを前記本体に向けさせることを含む、実施形態1に記載の方法。
[実施形態11]前記本体が前記前駆物質及び前記結合剤を含む成分の均一な混合物を含む、実施形態1に記載の方法。
[実施形態12]前記光学素子が導波管である、実施形態1に記載の方法。
[実施形態13]前記画像の通り露光する工程が、非ホログラフィックに行われる、実施形態1に記載の方法。
[実施形態14]前記前駆物質が、少なくとも1つの芳香族(メタ)アクリレートモノマーを含む、実施形態1に記載の方法。
[実施形態15]前記前駆物質が、フッ素化部分を含む少なくとも1つの芳香族(メタ)アクリレートを含む、実施形態1に記載の方法。
[実施形態16]前記前駆物質が、(b)少なくとも1つの多官能性(メタ)アクリレートモノマー0.5〜50重量部当たり、2−(1−ナフトキシ)エチル(メタ)アクリレート、2−(2−ナフトキシ)エチル(メタ)アクリレート、フェノキシ(メタ)アクリレート、及びそれらの混合物の少なくとも1つを10〜100重量部、含む、実施形態1に記載の方法。
[実施形態17]前記多官能性(メタ)アクリレートモノマーが、トリメチロールプロパントリ(メタ)アクリレート(TMPTA)、ヘキサンジオールジ(メタ)アクリレート、テトラエチレングリコールジ(メタ)アクリレート、及びそれらの混合物の少なくとも1つを含む、実施形態16に記載の方法。
[実施形態18]第1の光デバイスを第2の光デバイスに連結する方法であって、
(a)光硬化性官能価を含む成分中に少なくとも部分的に封入された、部分的に形成された第1の光学素子を備える第1の光デバイスを提供する工程であって、前記部分的に形成された第1の光学素子が、光硬化性材料を含む領域によって前記第1の光デバイスの境界から隔置されている端部を有する、工程と、
(b)前記第1の光学素子の前記端部が、第2の光デバイスに組み込まれた第2の光学素子の端部と整列して少なくとも略並置されるように、前記第1の光デバイスを前記第2の光デバイスに隣接して配置し、光硬化性材料を含有する領域が前記端部の間に配置される工程と、
(c)前記第1及び第2の光学素子の前記端部が相互に光学的に連結される条件下で前記領域の少なくとも一部分を光硬化する工程と、を含む方法。
[実施形態19]第1の光デバイスを第2の光デバイスに連結する方法であって、
(a)結合剤、光硬化性母材前駆物質、及び多光子光開始剤系を含む成分中に少なくとも部分的に封入された、部分的に形成された第1の光学素子を備える第1の光学素子デバイスを提供する工程であって、前記部分的に形成された光学素子が、本体の境界から隔置されている端部を有し、多光子光硬化性領域が前記端部と前記境界との間に並置される工程と、
(b)前記第1の光学素子に連結される端部を有する第2の光学素子を備える第2の光学素子デバイスを提供する工程と、
(c)前記第1の光学素子デバイスを前記第2の光学素子デバイスに隣接して配置して、前記第1及び第2の光学素子の前記端部を互いに整列して少なくとも略並置し、前記多光子光硬化性領域が前記端部の間に配置される工程と、
(d)前記第1及び第2の光学素子の前記端部が相互に光学的に連結される条件下で前記領域の少なくとも一部分を光硬化する工程と、を含む方法。
[実施形態20]3次元光学素子の少なくとも一部分と、
前記素子の少なくとも一部分を封入する高分子母材と、を含む光デバイスであって、
前記光学素子が、実質的に非拡散性の結合剤と、拡散種を含む光硬化性前駆物質と、多光子光開始剤系と、を含む本体の画像の通りの多光子重合を引き起こす工程を含む方法によって形成された、光硬化エネルギーフルエンスでブランケット照射されている光デバイス。
Claims (2)
- 第1の光デバイスを第2の光デバイスに連結する方法であって、
(a)硬化して本体を形成することができる、光硬化性材料中に封入された、部分的硬化により部分的に形成された第1の光学素子を備える第1の光デバイスを提供する工程であって、前記部分的に形成された第1の光学素子が、前記光硬化性材料を含む領域によって前記第1の光デバイスの境界から隔置されている端部を有する、工程と、
(b)前記第1の光学素子の前記端部が、第2の光デバイスに組み込まれた第2の光学素子の端部と整列して少なくとも略並置されるように、前記第1の光デバイスを前記第2の光デバイスに隣接して配置し、前記光硬化性材料を含有する領域が前記第1及び第2の光学素子の端部の間に配置される工程と、
(c)前記第1及び第2の光学素子の前記端部が相互に光学的に連結される条件下で前記光硬化性材料を含有する領域の少なくとも一部分を光硬化する工程と、を含む方法。 - 第1の光デバイスを第2の光デバイスに連結する方法であって、
(a)結合剤、光硬化性母材前駆物質、及び多光子光開始剤系を含む成分中に封入された、部分的硬化により部分的に形成された第1の光学素子を備える第1の光学素子デバイスを提供する工程であって、ここで、前記成分は硬化して本体を形成することができ、前記部分的に形成された第1の光学素子が、前記本体の境界から隔置されている端部を有し、前記成分の光硬化性母材前駆物質で構成される多光子光硬化性領域が前記端部と前記境界との間に並置される工程と、
(b)前記第1の光学素子に連結される端部を有する第2の光学素子を備える第2の光学素子デバイスを提供する工程と、
(c)前記第1の光学素子デバイスを前記第2の光学素子デバイスに隣接して配置して、前記第1及び第2の光学素子の前記端部を互いに整列して少なくとも略並置し、前記多光子光硬化性領域が前記端部の間に配置される工程と、
(d)前記第1及び第2の光学素子の前記端部が相互に光学的に連結される条件下で前記多光子光硬化性領域の少なくとも一部分を光硬化する工程と、を含む方法。
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JP2011186493A (ja) | 2011-09-22 |
EP1295179A2 (en) | 2003-03-26 |
US20100027956A1 (en) | 2010-02-04 |
AU2001268465A1 (en) | 2001-12-24 |
US7601484B2 (en) | 2009-10-13 |
JP2004503813A (ja) | 2004-02-05 |
KR100810547B1 (ko) | 2008-03-18 |
WO2001096917A2 (en) | 2001-12-20 |
KR20030017995A (ko) | 2003-03-04 |
US8530118B2 (en) | 2013-09-10 |
JP4786858B2 (ja) | 2011-10-05 |
JP5400090B2 (ja) | 2014-01-29 |
JP2013109379A (ja) | 2013-06-06 |
EP1295179B1 (en) | 2013-05-22 |
US20050208431A1 (en) | 2005-09-22 |
US7014988B2 (en) | 2006-03-21 |
US20060078831A1 (en) | 2006-04-13 |
WO2001096917A3 (en) | 2002-05-10 |
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