JPS5829630A - Manufacture of optical part - Google Patents

Abstract

PURPOSE:To obtain inexpensively an optical part good in accuracy of the surface, by providing a photo-setting resin layer on a plastic substrate surface, and a releasing agent layer and a metal reflective layer on a surface of a matrix, bringing them into firm contact with each other, irradiating an activation energy beam on the photo-setting resin layer, and separating the matrix at the releasing agent layer from the matrix. CONSTITUTION:A photo-setting resin (e.g. an ultraviolet-curing resin, etc.) layer 2 is formed on the surface of a plastic substrate 1 (e.g. a polymethyl methacrylate resin, etc.), and after a releasing agent (e.g. a polydimethyl siloxane, etc.) layer 4 and then a metal reflective film 5 (e.g. an Al deposited film, etc.) are successively formed on the surface of the matrix 3 for an optical part to be produced, the photo-setting resin layer 2 and the metal reflective layer 5 are brought into firm contact with each other. Then an activation energy beam (e.g. ultraviolet beam, etc.) is irradiated to set the photo-setting resin layer 2, and the matrix 3 is separated with the aid of the releasing agent layer 4 from the plastic substrate 1 to obtain the intended reflective optical part.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing an optical component, particularly a method for manufacturing an optical component, and in particular a method for manufacturing an optical component.
The present invention relates to a method for manufacturing a reflective optical component.

In the conventional manufacturing method of optical components, for example, when plastic is used as the main body or base of the optical component,
The injection molding method and the compression molding method were used. However, although these manufacturing methods are low in cost, the more complex the shape of the optical component, the worse the transferability from the mold, and the more difficult it becomes to obtain the necessary optical properties. In particular, when trying to obtain a flat surface such as a reflective surface, depending on the molding strip A/1, problems such as "Kl-sink" may occur, and no matter how good the surface area of the molding strip A/1 is, it is difficult to faithfully reproduce this. 111 There are many things that cannot be done. In addition, Jl, ft Niblastik t4 (
4<, A).

Anti-Q-1 is formed by vaporizing a thin film of metal such as Ag or Or.
1 rji w 1, the radiant heat from the evaporation source is 1
: Liblast, the substrate may be deformed, or the evaporated metal may be 1.1
When attaching the product, the surface of the plastic substrate may become partially distorted due to the heat. As a part manufacturing method, I(
1P, jizu, 1. There is a replica method that transfers the shape of IJI; be.

1] The object of the present invention is to provide a method for manufacturing an optical component using cheap plastic as a substrate, and having good optical properties, especially reflection. It's about doing. In this invention, a plus deck 1"+6: Q= is formed into a shape similar to the desired optical component by a molding method, etc., as a base, a photocurable resin layer is provided on the +, and a prototype is formed. A mold release agent layer and a metal reflective film layer are all sequentially provided on the mold of the optical component that will be used, and both are ri.
After bonding to the metal reflective layer, the photocurable resin layer is cured by irradiating it with mono-occupant energy rays such as ultraviolet rays, and is shaped into the shape of the matrix, and the metal reflective layer is bonded to the photocurable resin layer. It is characterized in that an optical component is obtained by transferring it to a plastic substrate through a plastic substrate.

An embodiment of the present invention will be described below with reference to FIG.

First, a mold for injection molding of a metal or glass plate whose surface has been finished by optical RIJr polishing is placed in a molding machine (-J), and an acrylic resin or the like is injected into it to form a substrate 1 that will become an optical component. The base of this optical component is
It has a certain degree of surface accuracy, and there is a photocurable resin layer 2 on the surface.
is provided by a method such as coating. On the other hand, the prototype matrix, metal, glass, etc., was formed by optical
After providing the mold release agent layer 4 on the surface by coating, spraying, vacuum deposition, etc., A4. Ag,
A metal reflective film layer 5 of Or, Au, etc. is formed to a thickness of about 500 nm by vacuum evaporation, sputtering, ion plate ink, or the like. It is preferable that at least one of the plastic substrate 1 and the matrix 5 be made of a translucent material. Then, the body 1 and the matrix locus are shown in Figure 1 (B).
; After bonding the curable resin layer 2 and the metal reflective film layer 5 so that they are in close contact with each other, an active energy ray 6 such as ultraviolet rays is directed toward the photocurable resin layer 2. Then, the thin photocurable resin layer 2 is cured following the pattern of the IU matrix, and the metal reflective film layer 5 is transferred to the plastic substrate 1 via the photocurable resin layer 2. Therefore, plastic J, l;
Figure 1 (C) As shown in IC, IJ type: R')
Ir, t are exactly the same!耘? A reflective optical component with high surface precision can be obtained.

Next to the mold release agent layer 4 in Example R, as shown in FIG.
is applied to a thickness of approximately +50 nm using a vacuum evaporation method, a sputtering method, an ion plate ink method, etc., and then a metal reflective film layer 5 is provided on the surface of the completed optical component. Since the transparent WI'j I film layer 7 is formed, it functions as a protective film for the metal reflective film layer 5.

Further, as shown in FIG. 5, on the mold release agent layer 4, T 1
．． 02 to a thickness of about 60 nm, and then MgF on top of it.
2 to a thickness of about 100 nm, two transparent thin film layers 7 and 8 are provided, and a metal reflective film layer 5 is formed thereon. Obtainable.

Furthermore, instead of the transparent thin film layer 7 in FIG.
? In705 f with a modulus of approximately 2.0, thickness approximately +40 nm
fC can be formed to form a transparent conductive layer. This is formed by a sputtering method or the like in an atmosphere of 02 gas. Then, by passing a minute current through this transparent conductive layer, it can have both the functions of protecting the surface of the metal reflective film and preventing condensation. In2O3 is formed to a thickness of about 140 nm as a conductive layer, and 8 transparent thin film layers of MgF
2 to a thickness of about 1100 nm to form a dielectric layer.
Therefore, the protection of the metal reflective film 5, the reflective layer 1 and dew condensation +f]
It can have three effects: 1/month.

In addition to the injection molding method (11), the plastic substrate 1 can be formed by a compression molding method, an injection compression molding method, or a molding method such as the injection compression molding method. Methacrylate resin, polycarbonate resin, styrene resin, ABS resin, As resin 3c and glue 41.
Plasticity resin and diethylene glyco-7 resin 7
Repower-bonate polymer (product name manufactured by ppc [;R59)]
, thermosetting resins such as Evogin resin. JC7(i
Il! In addition to ultraviolet curing resins, the curing resin 2 may include vitrifying monomers such as methacrylic acid esters that are cured by r-rays. It is also possible to use materials that are polymerized and cured by F-rays or the like. K) 1. As a cleaning agent, a silicone oil containing polymethylsiloxane or the like can be used. As the transparent thin film layer 7.8, Sj, 02, Sin, At203. MgF
2. GaF2+No3AtF6. TiO2, CeO
2, ZrO2, ZuS, etc. can be used.

These thin film layers are composed of [1 according to 7 or lI /z [
6. The method according to the present invention can be applied to all kinds of solar components that require a reflective film, but it can also be applied to micro-roof mirror arrays and roof mirrors as shown in Fig. 4. It is particularly effective for , corner gave prisms, rotating polygon mirrors, plane mirrors, etc.

[Brief explanation of the drawing]

FIG. 1 is a diagram showing an example of the optical component manufacturing method according to the present invention, FIGS. 2 and 5 are diagrams showing other examples of the optical component manufacturing method according to the present invention, and FIG. 4 is a diagram showing an example of the optical component manufacturing method according to the present invention. FIG. 3 is a diagram showing an example of an optical component formed by the method. 1...Plastink base, 2...Photocurable resin layer,
Ro... (Mold, 4... Release agent layer, 5... Metal reflective film layer, 61. Active energy rays, 7, 8... Transparent thin film layer. Ku Mei 161- (D

Claims (1)

[Scope of Claims] 1 Plastic base M
+', lli'j agent layer and metal reflective film layer Ill[
The step of forming the Jt, (the illumination resin layer and the metal reflective film layer are bonded to 11), and then the photocurable resin layer is cured by irradiating active energy rays. [11] Separating the above-mentioned INJ Koto J from the plastic substrate through the 11-layer agent layer. 2. MiJ Plus deck J, C (4＼ or injection molding υ, -1 for molding methods such as cutting compression molding method, pressure & i cedar method etc.
XS115 Patent to be created +: l'j range of first apex 1
1ν method. 6 Said plastino substrate - or l:J: 1114
) at least one of them has optical transparency.
1 and 2] Patent 1i1 Scope No. 11'l'
The method described in j. 4. The method according to claim 1, wherein at least one transparent dielectric layer is formed between the mold release agent layer and the metal reflective film layer formed in the I-shaped shape. 5. The method according to item 4 of the scope of Patent No. 811, wherein at least one of the transparent dielectric layers is replaced with a transparent conductor layer Vrc.