WO2003058291A1 - An optical element and method for manufacturing the same - Google Patents

An optical element and method for manufacturing the same Download PDF

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Publication number
WO2003058291A1
WO2003058291A1 PCT/SE2003/000062 SE0300062W WO03058291A1 WO 2003058291 A1 WO2003058291 A1 WO 2003058291A1 SE 0300062 W SE0300062 W SE 0300062W WO 03058291 A1 WO03058291 A1 WO 03058291A1
Authority
WO
WIPO (PCT)
Prior art keywords
printing
layer
optical element
substrate
refractive
Prior art date
Application number
PCT/SE2003/000062
Other languages
French (fr)
Inventor
Leif Bergstedt
Björn LÖVING
Original Assignee
Imego Ab
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from SE0200091A external-priority patent/SE0200091L/en
Application filed by Imego Ab filed Critical Imego Ab
Priority to AU2003235774A priority Critical patent/AU2003235774A1/en
Publication of WO2003058291A1 publication Critical patent/WO2003058291A1/en

Links

Classifications

    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B3/00—Simple or compound lenses
    • G02B3/0006—Arrays
    • G02B3/0037—Arrays characterized by the distribution or form of lenses
    • G02B3/0056—Arrays characterized by the distribution or form of lenses arranged along two different directions in a plane, e.g. honeycomb arrangement of lenses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/141—Processes of additive manufacturing using only solid materials
    • B29C64/153—Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
    • B41M3/00—Printing processes to produce particular kinds of printed work, e.g. patterns
    • B41M3/003—Printing processes to produce particular kinds of printed work, e.g. patterns on optical devices, e.g. lens elements; for the production of optical devices
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B3/00—Simple or compound lenses
    • G02B3/0006—Arrays
    • G02B3/0012—Arrays characterised by the manufacturing method

Definitions

  • the present invention relates to a method for producing an optical element, preferably a refractive element, comprising a carrier and an element part.
  • the invention also relates to 0 optical elements produced through the method.
  • Microlenses and other refractive elements may for example be used for coupling light from 5 a laser to an optical fibre and from the optical fibre to a photo-detector.
  • monolithic microlenses and microlens arrays are manufactured on opto-electronic devices and other substrates by using sharp edge pedestals to confine the lateral flow of a molten lens material.
  • the lens material wets the upper surfaces of the pedestals, but the pedestal edges confine the flow, so the lens material conforms to the shape of the pedestal surface and assumes a semi-arcuate profile due to its surface tension.
  • Spin coating and photolithographic patterning may be employed to form the pedestals and to deposit the lens material thereon. The lens material is melted after being deposited, so the pedestals advantageously are stabilized to prevent them from deforming at the temperature of the molten lens material.
  • Desired grey scale patterns may be created by varying the thickness of a light-absorbing layer. Such variations in thickness may be created using multiple binary masks. Desired grey scale patterns may also be created on a computer using available software and then 55 imaged onto film or a glass film plate. Direct contact or proximity printing is then used to transfer the true grey scale pattern onto photoresist. The photoresist is then etched, thereby forming the desired pattern therein. All portions of the desired pattern are simultaneously formed in the photoresist. The etched photoresist is then used to photolithographically fabricate either the optical element itself or a master element to be used in injection moulding or other replication techniques. The grey scale mask itself may be used repeatedly to generate photoresists. The imaging is particularly useful for forming optical elements having a plurality of arrays of refractive elements. 5
  • Raster lines may be printed using different numbers of jets in each group in different passes. Moreover, full and partial head randomization is available. Selected raster lines are printed in one direction, although the print head prints in two directions. Furthermore, raster lines printing may be interlaced, and deposition order may
  • the main object of the present invention is to present a novel method of manufacturing an optical element, preferably a refractive element such as one or several of micro-lenses or gratings.
  • Advantages of the invention also involve allowing mass production of micro-lens arrays, !5 gratings etc. with very good accuracy.
  • an optical element preferably a refractive element, comprising a carrier and an element part.
  • the method comprises selectively depositing on said substrate through a printing operation at least one layer constituting
  • said printing operation comprises one of offset printing, screen-printing, liquid jet printing or electrostatic printing.
  • the selective deposition comprises deposition of several layers of different characteristics or the layer may consist of different material.
  • the layer can be dot shaped for lenses and strip for a
  • the invention also relates to an optical element, preferably a refractive element, comprising a carrier and an element part, wherein the element part comprises at least one layer selectively deposited on said substrate through a printing operation.
  • an optical element preferably a refractive element, comprising a carrier and an element part, wherein the element part comprises at least one layer selectively deposited on said substrate through a printing operation.
  • Fig. 1 schematically illustrates an embodiment of the invention comprising from above
  • FIG. 2 illustrates a cross-section along line II-II in Fig. 1,
  • Fig. 3 illustrates a cross-sectional production step
  • Fig. 4 illustrates a cross-sectional view of another production step.
  • the printing method may include any of modified versions of screen-printing, offset printing, electrostatic deposition or "fluid-jet” printing.
  • Fig. 1 shows an array 10 15 of micro-lenses 11 arranged on a substrate 12.
  • Fig. 2 is a cross-section along line II-II in Fig. 2.
  • the substrate 11 may consist of an optically transparent material such as glass or ceramic material.
  • Figs. 3 and 4 One method of manufacturing the lenses is illustrated in Figs. 3 and 4.
  • selective layers of an optically transparent material such as glass, plastic or the like are deposited in layers.
  • screen-printing is used to deposit the layers.
  • patterns of lenses consisting of layers are applied to a screen 13, transferring onto the substrate only through the porous segments 14.
  • the stacked layers are arranged in decreasing size so that a substantially pyramid shape is obtained.
  • Each layer 15a, 15b and S5 15c can consist of same material or same material having different characteristics, such as different refractive indexes.
  • different material such as plastic and glass can be combined.
  • Using selective multilayer deposition of glass allows glass formations (lenses) having different viscosity/surface tension etc. Different characteristics and material types allow mass production of new types of optical elements.
  • each stack is exposed to heat, which melts/fuses the each stack of layer into a solid, substantially half spherical form, as illustrated in Figs. 1 and 2.
  • the deposition of the layers can also be carried out using offset printing, in which melt glass (or plastic) is spread on a metal plate with etched patterns, then transferred to an intermediary surface and finally applied to substrate by pressing the it against the intermediary surface.
  • the invention is also suitable for producing other optical elements such as gratings.
  • oblong strips of glass/plastic are printed onto a substrate, instead of dots.
  • Different types of material and material with different characteristics can be used to produce different strips on same substrate.
  • different strips of different material can be printed in sequences to provide a desired grating.
  • one strip can include different material/characteristics.
  • the surface of the strips can be treated, e.g. by grinding or polishing to obtain desired features.

Landscapes

  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • General Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)

Abstract

The present invention relates to a method for producing an optical element (10) and an optical element, preferably a refractive element, comprising a carrier (12) and an element part (11). Said element part comprises at one layer (15a, 15b, 15c) selectely deposited on said substrate through a printing operation.

Description

TITLE
AN OPTICAL ELEMENT AND METHOD FOR MANUFACTURING THE SAME
5
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a method for producing an optical element, preferably a refractive element, comprising a carrier and an element part. The invention also relates to 0 optical elements produced through the method.
BACKGROUND OF THE INVENTION
Microlenses and other refractive elements may for example be used for coupling light from 5 a laser to an optical fibre and from the optical fibre to a photo-detector.
A number of methods for manufacturing an array of micro-lenses are known. Example of some methods are discussed in patent literature, for example US 4,689,291, US 6,071,652, JP 0660607 and JP 10123305US 5,536,455 and EP614 096-A1.
!0
According to US 4,689,291, monolithic microlenses and microlens arrays are manufactured on opto-electronic devices and other substrates by using sharp edge pedestals to confine the lateral flow of a molten lens material. The lens material wets the upper surfaces of the pedestals, but the pedestal edges confine the flow, so the lens material conforms to the shape of the pedestal surface and assumes a semi-arcuate profile due to its surface tension. Spin coating and photolithographic patterning may be employed to form the pedestals and to deposit the lens material thereon. The lens material is melted after being deposited, so the pedestals advantageously are stabilized to prevent them from deforming at the temperature of the molten lens material.
(0
In US 6,071,652, grey scale masks used to create optical elements are formed. Desired grey scale patterns may be created by varying the thickness of a light-absorbing layer. Such variations in thickness may be created using multiple binary masks. Desired grey scale patterns may also be created on a computer using available software and then 55 imaged onto film or a glass film plate. Direct contact or proximity printing is then used to transfer the true grey scale pattern onto photoresist. The photoresist is then etched, thereby forming the desired pattern therein. All portions of the desired pattern are simultaneously formed in the photoresist. The etched photoresist is then used to photolithographically fabricate either the optical element itself or a master element to be used in injection moulding or other replication techniques. The grey scale mask itself may be used repeatedly to generate photoresists. The imaging is particularly useful for forming optical elements having a plurality of arrays of refractive elements. 5
However, all of the above mentioned documents relate to providing a layer of an optically transparent layer, parts of which are removed in another step to form sections, which are melted to form micro-lenses.
0 US 6,136,252, describes techniques for printing raster lines in a selective deposition modeling (SDM) system. Raster lines may be printed using different numbers of jets in each group in different passes. Moreover, full and partial head randomization is available. Selected raster lines are printed in one direction, although the print head prints in two directions. Furthermore, raster lines printing may be interlaced, and deposition order may
5 be changed between layers. However, this invention does not mention or hint a method for manufacturing optical refractive elements.
SUMMARY OF THE INVENTION
:0 The main object of the present invention is to present a novel method of manufacturing an optical element, preferably a refractive element such as one or several of micro-lenses or gratings.
Advantages of the invention also involve allowing mass production of micro-lens arrays, !5 gratings etc. with very good accuracy.
Therefore a method for producing an optical element, preferably a refractive element, comprising a carrier and an element part is provided. The method comprises selectively depositing on said substrate through a printing operation at least one layer constituting
•0 said element part. According to one aspect of the invention, said printing operation comprises one of offset printing, screen-printing, liquid jet printing or electrostatic printing. Preferably, the selective deposition comprises deposition of several layers of different characteristics or the layer may consist of different material. Thus, at least one layer is melted to form said element. The layer can be dot shaped for lenses and strip for a
(5 grating.
The invention also relates to an optical element, preferably a refractive element, comprising a carrier and an element part, wherein the element part comprises at least one layer selectively deposited on said substrate through a printing operation.
BRIEF DESCRIPTION OF THE DRAWINGS
5
In the following, the invention will be further described in a non-limiting way with reference to the accompanying drawings in which:
Fig. 1 schematically illustrates an embodiment of the invention comprising from above,
0 Fig. 2 illustrates a cross-section along line II-II in Fig. 1,
Fig. 3 illustrates a cross-sectional production step, and
Fig. 4 illustrates a cross-sectional view of another production step.
DETAILED DESCRIPTION OF THE EMBODIMENTS
5
In the following, the invention will be described in a non-limited way with reference to micro-lenses, according to one aspect of the invention. However, it should be understood that other refractive elements fall within the scope of the invention. According to the main aspect of the invention, elements are produced using a printing method on a substrate,
10 whereby a layer(s) of suitable material is disposed onto the substrate. The printing method may include any of modified versions of screen-printing, offset printing, electrostatic deposition or "fluid-jet" printing.
One preferred embodiment of the invention is illustrated in Fig. 1, which shows an array 10 15 of micro-lenses 11 arranged on a substrate 12. Fig. 2 is a cross-section along line II-II in Fig. 2. The substrate 11 may consist of an optically transparent material such as glass or ceramic material.
One method of manufacturing the lenses is illustrated in Figs. 3 and 4. In his example )0 selective layers of an optically transparent material such as glass, plastic or the like are deposited in layers. In this case screen-printing is used to deposit the layers. Accordingly, patterns of lenses consisting of layers are applied to a screen 13, transferring onto the substrate only through the porous segments 14. The stacked layers are arranged in decreasing size so that a substantially pyramid shape is obtained. Each layer 15a, 15b and S5 15c can consist of same material or same material having different characteristics, such as different refractive indexes. In addition, different material such as plastic and glass can be combined. Using selective multilayer deposition of glass, allows glass formations (lenses) having different viscosity/surface tension etc. Different characteristics and material types allow mass production of new types of optical elements.
When all stacks of layers are in place, each stack is exposed to heat, which melts/fuses the each stack of layer into a solid, substantially half spherical form, as illustrated in Figs. 1 and 2.
The deposition of the layers can also be carried out using offset printing, in which melt glass (or plastic) is spread on a metal plate with etched patterns, then transferred to an intermediary surface and finally applied to substrate by pressing the it against the intermediary surface.
The invention is also suitable for producing other optical elements such as gratings. In this case oblong strips of glass/plastic are printed onto a substrate, instead of dots. Different types of material and material with different characteristics can be used to produce different strips on same substrate. Furthermore, different strips of different material can be printed in sequences to provide a desired grating. Also, one strip can include different material/characteristics. The surface of the strips can be treated, e.g. by grinding or polishing to obtain desired features.
In fluid jet or electrostatic printing method, melted or very small particles of glass/plastic are used, which are blown over the substrate or disposed through electrostatic.
The invention is not limited to the shown embodiments but can be varied in a number of ways without departing from the scope of the appended claims and the arrangement and the method can be implemented in various ways depending on application, functional units, needs and requirements etc.

Claims

1. A method for producing an optical element (10), preferably a refractive element, comprising a carrier (12) and an element part (11),
5 characterised in selectively depositing on said substrate through a printing operation at least one layer (15a, 15b, 15c) constituting said element part.
2. The method of claim 1, wherein said printing operation comprises one of offset 0 printing, screen-printing, liquid jet printing or electrostatic printing.
3. The method of claim 1, wherein said selective deposition comprises deposition of several layers of different characteristics.
5 4. The method according to any one of claims 1-4, wherein said at least one layer is melted to form said element.
5. The method according to any one of claims 1-3, wherein said layer is dot shaped.
!0 6. The method according to any one of claims 1-3, wherein said layer is a strip.
7. The method according to claim 3, wherein said layer consists of different material.
8. A lens element produced according to any of claims 1-7.
!5
9. A microlens element produced according to any of claims 1-7.
10. A microlens array produced according to any of claims 1-7.
(0 11. A grating element produced according to any of claims 1-7.
12. An optical element (10), preferably a refractive element, comprising a carrier (12) and an element part (11), characterised in $5 that said element part comprises at least one layer (15a, 15b, 15c) selectively deposited on said substrate through a printing operation.
13. The optical element of claim 12, wherein said printing operation comprises one of offset printing, screen-printing, liquid jet printing or electrostatic printing.
PCT/SE2003/000062 2002-01-11 2003-01-13 An optical element and method for manufacturing the same WO2003058291A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU2003235774A AU2003235774A1 (en) 2002-01-11 2003-01-13 An optical element and method for manufacturing the same

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US34697702P 2002-01-11 2002-01-11
US60/346,977 2002-01-11
SE0200091A SE0200091L (en) 2002-01-11 2002-01-11 An optical element and a method for manufacturing the same
SE0200091-7 2002-01-11

Publications (1)

Publication Number Publication Date
WO2003058291A1 true WO2003058291A1 (en) 2003-07-17

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WO (1) WO2003058291A1 (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN108541238A (en) * 2015-10-27 2018-09-14 洛桑联邦综合理工学校(Epfl) It is stacked shape image by the interaction synthesis of the superimposed layer of light and lenslet grating

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6136252A (en) * 1995-09-27 2000-10-24 3D Systems, Inc. Apparatus for electro-chemical deposition with thermal anneal chamber

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6136252A (en) * 1995-09-27 2000-10-24 3D Systems, Inc. Apparatus for electro-chemical deposition with thermal anneal chamber

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN108541238A (en) * 2015-10-27 2018-09-14 洛桑联邦综合理工学校(Epfl) It is stacked shape image by the interaction synthesis of the superimposed layer of light and lenslet grating
US10899161B2 (en) 2015-10-27 2021-01-26 Ecole Polytechnique Federale De Lausanne (Epfl) Synthesis of superpostion shape images by light interacting with superposed layers of lenslet gratings

Also Published As

Publication number Publication date
AU2003235774A1 (en) 2003-07-24

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