METHOD FOR MANUFACTURING OPTICAL ELEMENT AND OPTICAL ELEMENT

The present invention relates to an optical element, and to a method for manufacturing the same.

Molding processes are frequently employed in the manufacture of optical elements (for example, see Patent Document 1), For example, in the case of a molding process for a phase Fresnel lens, which is a bonded-multilayer diffractive optical element, a first resin material is packed into a gap between a disk-shaped glass substrate and a molding die positioned in proximity to the glass substrate, and a first resin layer having a diffraction grating is molded. Then, a molding die is pressed against a second resin material having a different refractive index than the first resin material, which has been dripped onto the first resin layer, and a second resin layer is molded. Consequently, a bonded-multilayer diffractive optical element be molded.

Japanese Patent Publication No. 4029208 (B2)

However, during formation of multiple layers by the method mentioned above, when the outside diameter of the second layer is greater than the outside diameter of the first layer, there is a tendency for gases to get trapped inside the external circumferential part of the second layer which protrudes out from, the first layer, creating a risk of air bubbles becoming incorporated into the optical element, and of degraded appearance.

With the foregoing in view, it is an object of the present invention to provide a method for manufacturing an optical element that prevents incorporation of air bubbles, and an optical element manufactured thereby.

To achieve this object, the method for manufacturing an optical element provides a method for manufacturing an optical element, by stacking and molding individual layers of a plurality of layers on a base material, wherein when those among the plurality of layers constituting the second and subsequent layers as counted from the base material are to be molded, the molding is conducted in such a, way that the external circumferential part of the layer to be molded is located inward from the external circumferential part of the layer located closer towards the base material than the layer in question.

In the above method, in preferred practice, the plurality of layers constitutes two layers, and during molding of the layer constituting the second of the two layers as counted, from the base material, the molding is conducted in such a way that the external circumferential part, of the second layer is located inward from the external circumferential part of the first layer, which is located closer towards the base material than the second layer.

In the above manufacturing method, the first layer and the second layer are respectively molded from a resin material, and the viscosity of the resin material employed during molding of the second layer can be 3000 to 7000 mPa·s.

Additionally, in the above manufacturing method, in preferred practice, the first layer, which has a diffraction grating, is molded onto the base material, the second layer is stacked and molded onto the first layer so as to become bonded to the diffraction grating, and the resin material employed during molding of the first layer having a viscosity of 200 to 800 mPa·s.

Additionally, in the above manufacturing method, each of the layers is respectively molded from a resin material, and the viscosity of the resin material employed during molding of at least any one of the plurality of layers can be 3000 to 7000 mPa·s.

Additionally, in the above manufacturing method, each of the layers preferably has a thickness of 50 to 400 μm.

The optical element according to a first invention is manufactured by the aforementioned method for manufacturing an optical element.

The optical element according to a second invention is provided with a base material, and with a plurality of layers stacked and molded onto the base material, the external circumferential part of those among the plurality of layers constituting the second and subsequent layers as counted from the base material, being located inward from the external circumferential part of the layer located closer towards the base material than the layer in question.

In the second optical element, in preferred practice, the plurality of layers constitutes two layers, the external circumferential part of the layer constituting the second of the two layers, as counted from the base material, being located inward from the external circumferential part of the first layer, which is located closer towards the base material than the second layer.

Additionally, in the second optical element, the first layer and the second layer are respectively molded from a resin material, and the viscosity of the resin material employed during molding of the second layer can be 3000 to 7000 mPa·s.

Additionally, in the second optical element, in preferred practice, the first layer, which has a diffraction grating, is molded onto the base material, the second layer is stacked and molded onto the first layer so as to become bonded, to the diffraction grating, and the resin material employed during molding of the first layer having a viscosity of 200 to 800 mPa·s.

Additionally, in the second optical element, each of the plurality of layers is respectively molded from a resin material, and the viscosity of the resin material employed during molding of at least any one of the plurality of layers can be 3000 to 7000 mPa·s.

Additionally, in the second optical element, each of the plurality of layers preferably has a thickness of 50 to 400 μm, respectively.

According to the present invention, incorporation of air bubbles info an optical element can be prevented.

The preferred embodiments of the present invention are described below, making reference to the accompanying drawings. As an example of the optical element in a first embodiment, a phase Fresnel lens (hereinbelow designated as “PF lens 1”), which is a bonded-multilayer diffractive optical element, is shown in FIG. 2. The PF lens 1 of the first embodiment is constituted by a glass substrate 2, a first resin layer 4 molded onto the glass substrate 2, and a second resin layer 6 stacked and molded onto the first resin layer 4. The glass substrate 2 is molded into a disk shape from a transparent glass material, and a primer layer 3 of a silane coupling agent is formed on a one face of the glass substrate 2 (the face to be joined to the first resin layer 4).

The resin layer 4, which is the first layer counting from the glass substrate 2, is formed to disk shape front a transparent resin material, and a diffraction grating 5 in which a plurality of ring zones are arrayed in concentric circles is formed on a one face of the first resin layer 4 (the face to be joined to the second resin layer 6). The diameter of the first resin layer 4 is slightly smaller than the diameter of the glass substrate 2 (and is larger than the effective diameter of the PF lens 1), with the external circumferential part of the first resin layer 4 being located inward of the external circumferential part of the glass substrate 2. Also, the thickness of the first resin layer 4 is 50 μm to 400 μm, for example. For simplicity in description in the drawings, the diffraction grating 5 is depicted as having a reduced number of ring zones; however, the actual number of ring zones would be sufficiently great as to be serviceable. Also, in the drawings, hatching is omitted in cross sectional views, for simplicity in description.

The resin layer 6, which is the second layer counting from the glass substrate 2, is molded to disk shape from a transparent resin material having a different refractive index than the first resin layer 4. The diameter of the second resin layer 6 is slightly smaller than the diameter of the first resin layer 4 (and is larger than the effective diameter of the PF lens 1), with the external circumferential part of the second resin layer 6 being located inward of the external circumferential part of the first, resin layer 4. Also, the thickness of the second resin layer 6 is 50 μm to 400 μm, for example.

The method for manufacturing the PF lens 1 constituted in the above manner is described with reference to the flowchart shown in FIG. 3. Firstly, the first resin layer 4 is molded and joined onto the glass substrate 2 (Step S101). During molding of the first resin layer 4, as shown in FIG. 1A, a liquid mixture of a silane coupling agent/ethyl alcohol/water (the water being made moderately acidic with acetic acid or the like) is applied by spin coating over the entire surface of a one face of the glass substrate 2, and baked to form a primer layer 3. A first molding die (mold) 10 having a predetermined diffraction grating is positioned adjacently to the one face of the glass substrate 2 on which the primer layer 3 has been formed, and as shown in FIG. 1B, an uncured resin 4a for molding the first resin layer 4 is packed into the gap between them. In this state, the resin 4a is irradiated with ultraviolet light at a predetermined exposure (for example, 2000-4000 mJ/cm²) from the other face of the glass substrate 2, curing the uncured resin 4a, which is then released from the mold.

Consequently, the first resin layer 4 having the diffraction grating 5 is molded through transfer of the grating shape of the first molding die 10 to the resin 4a, and the first resin layer 4 is joined to the one face of the glass substrate 2 via the primer layer 3. The resin material (resin 4a) employed for the first resin layer 4 is an ultraviolet-curing resin having a viscosity of 200 mPa·s to 800 mPa·s in the uncured state. During molding, the resin 4a is packed in such a way that the external circumferential part of the first resin layer 4 is located inward of the external circumferential part of the glass substrate 2.

Next, the second resin layer 6 is stacked and molded onto the first resin layer 4, becoming joined thereto (Step S102). During molding of the second resin layer 6, as shown in FIG. 1C, an uncured resin 6a for molding the second resin layer 6 is dripped onto the first resin layer 4; and as shown in FIG. 1D, a molding die (mold) 12 is placed against the dripped resin 6a, then cured with ultraviolet in the same manner as the first layer, and released from the mold. The surface (transfer surface) of the second molding die 12 is formed to a flat surface. The surface (transfer surface) of the second molding die 12 is determined according to the shape of the second resin layer 6, and may be a spherical face or aspherical face.

As shown in FIG. 1E, the second resin layer 6 is molded in such a way as to bond to the diffraction grating 5 at the other face, and the second resin layer 6 is joined to the one face of the first resin layer 4. The resin material (resin 6a) employed for the second resin layer 6 is an ultraviolet-curing resin having a viscosity, in the uncured state, of 3000 mPa·s to 7000 mPa·s. During molding, the second molding die 12 is brought into contact against the resin 6a in such a way that the external circumferential part of the second resin layer 6 is located inward of the external circumferential part of the first resin layer 4. In this way, the PF lens 1 in which the two resin layers 4, 6 are molded onto the glass substrate 2 is manufactured.

As a result, according to the first embodiment, because the external circumferential part, of the second resin layer 8 is located inward of the external circumferential part, of the first resin layer 4 which is located closer to the glass substrate 2 than the second resin layer 6, during molding, the external circumferential part of the resin 6a of the second layer does not protrude out from the first resin layer 4 so that gases become entrained inside, and air bubbles can be prevented from being incorporated into the PF lens 1.

The viscosity of the resin material (resin 6a) employed during molding of the second resin layer 6 is 3000 mPa·s to 7000 mPa·s, and in cases in which a resin material of such relatively high viscosity is employed for the second resin layer 6, when the external circumferential part of the resin material 6a of the second layer protrudes out from the first resin layer 4 during molding, gases would tend to became entrained therein. Therefore, incorporation of air bubbles into the PF lens 1 can be effectively prevented. The range of viscosity of the resin material (resin 6a) employed during molding of the second resin layer 6 can be from 4600 mPa·s to 5400 mPa·s.

The viscosity of the resin material, (resin 4a) employed during molding of the first resin layer 4 is 200 mPa·s to 800 mPa·s, and by employing a resin material of lower viscosity than the second resin layer 6 for the first resin layer 4, incorporation of air bubbles into the first resin layer 4 can be prevented. The range of viscosity of the resin material (resin 4a) employed during molding of the first resin layer 4 can be from 400 mPa·s to 600 mPa·s.

The thicknesses of the first resin layer 4 and the second resin layer 6 are respectively from 50 μm to 400 μm, and the two resin layers can be molded, as appropriate, within this range of thickness for each layer.

Next, a second embodiment of a PF lens is described while referring to FIG. 4. The PF lens 21 of the second embodiment is constituted by a first glass substrate 22, a first resin layer 24 molded onto the first glass substrate 22, a second resin layer 26 stacked and molded onto the first resin layer 24, and a second glass substrate 28 stacked onto and joined to the second resin layer 26. The first glass substrate 22 is molded to disk shape from a transparent glass material, and a primer layer 23 of a silane coupling agent is formed on a one face of the first glass substrate 22 (the face to be joined to the first resin layer 24),

The resin layer 24, which is the first layer counting from the first glass substrate 22, is formed into disk shape from a transparent resin material, and a diffraction grating 25 in which a plurality of ring zones are arrayed in concentric circles is formed on a one face of the first resin layer 24 (the face to be joined to the second resin layer 26). The diameter of the first resin layer 24 is slightly smaller than the diameter of the first glass substrate 22 (and is larger than the effective diameter of the PF lens 21), with the external circumferential part of the first resin layer 24 being located inward of the external circumferential part of the first glass substrate 22. Also, the thickness of the first resin layer 24 is 50 μm to 400 μm, for example.

The resin layer 26, which is the second layer counting from the first glass substrate 22, is molded to disk shape from a transparent resin material having a different refractive index than the first resin layer 24. The diameter of the second resin layer 26 is slightly smaller than the diameter of the first resin layer 24 (and is larger than the effective diameter of the PF lens 21), with the external circumferential part of the second resin layer 26 being located inward of the external circumferential part of the first resin layer 24. Also, the thickness of the second resin layer 26 is 50 μm to 400 μm, for example.

The second glass substrate 28 is molded to disk shape from a transparent glass material, and a primer layer 29 of a silane coupling agent is formed on the other face of the second glass substrate 28 (the face to be joined to the second resin layer 26).

The method for manufacturing the PF lens 21 constituted in the above manner is now described. The flow of the manufacturing method of the PF lens 21 according to the second embodiment is similar to that in the case of the first embodiment, and the description will employ the flowchart shown in FIG. 3. Firstly, the first resin layer 24 is molded and joined onto the first glass substrate 22 (Step S101). During molding of the first resin layer 24 onto the first glass substrate 22, as shown in FIG. 5A, a liquid mixture of a silane coupling agent/ethyl alcohol/water (the water being made moderately acidic with acetic acid or the like) is applied by spin coating over the entire surface of a one face of the first glass substrate 22, and baked to form a primer layer 23. A molding die (mold) 30 having a predetermined diffraction grating is positioned adjacently to the one face of the first glass substrate 22 onto which the primer layer 23 has been formed, and as shown in FIG. 5B, an uncured resin 24a for molding the first resin layer 24 is packed into the gap between them. In this state, the resin 24a is irradiated with ultraviolet light for a predetermined duration (for example, two minutes) from the other face of the first glass substrate 22, curing the uncured resin 24a, which is then released from the mold.

Consequently, the first resin layer 24 having the diffraction grating 25 is molded through transfer of the grating shape of the molding die 30 to the resin 24a, and the first resin layer 24 is joined to the one face of the glass substrate 22 via the primer layer 23. The resin material (resin 24a) employed for the first resin layer 24 is an ultraviolet-curing resin having a viscosity of 200 mPa·s to 800 mPa·s in the uncured state. During molding, the resin 24a is packed in such a way that the external circumferential part of the first resin layer 24 is located inward of the external circumferential part of the first glass substrate 22.

Next, the second resin layer 26 is stacked and molded onto the first resin layer 24, becoming joined thereto (Step S102). During molding of the second resin layer 26, as shown in FIG. 5C, an uncured resin 26a for molding the second resin layer 26 is dripped onto the first resin layer 24; and as shown in FIG. 5D, the second glass substrate 28 is placed against the dripped resin 26a, then cured with ultraviolet in the same manner as the first layer. At this time, the primer layer 29 has been formed on the other face of the second glass substrate 28 in the same manner as for the first glass substrate 22, and through contact of this primer layer 29 against the resin 26a, molding of the second resin layer 26 and joining of the second glass substrate 28 to the second resin layer 26 can be accomplished simultaneously.

Consequently, the second resin layer 26 is molded in such a way as to bond to the diffraction grating 25 at the other face, as well as joining the second resin layer 26 to the one face of the first resin layer 24, while simultaneously joining the second glass substrate 28 to the one face of the second resin layer 26 via the primer layer 29. The resin material (resin 26a) employed for the second resin layer 26 is an ultraviolet-curing resin having a viscosity, in the uncured state, of 3000 mPa·s to 7000 mPa·s. During molding, the second glass substrate 28 is brought into contact against the resin 26a in such a way that the external circumferential part of the second resin layer 26 is located inward of the external circumferential part of the first resin layer 24. In this way, the PF lens 21 of two molded resin layers 24, 26 between the two glass substrates 22, 28 is manufactured.

As a result, according to the second embodiment, advantageous effects comparable to those in the case of the first embodiment can be obtained. Moreover, according to the second embodiment, the second glass substrate 28, on which the primer layer 29 has been formed, is brought into contact against the resin 26a while molding the second resin layer 26, whereby molding of the second resin layer 26 and joining of the second glass substrate 28 to the second resin layer 26 can be accomplished simultaneously. Therefore, in the case of manufacture of the PF lens 21 by molding of the two resin layers 24, 26 between the two glass substrates 22, 28, the need to mold the second resin layer with a molding die is obviated, and the production process of the PF lens 21 can be simplified.

In the second embodiment mentioned above, the second resin layer 26 is molded while the second glass substrate 28 on which the primer layer 29 has been formed is brought into contact against the resin 26a; however, there is no limitation to this. For example, in the same manner as in the first embodiment as shown in FIGS. 1A to 1E, after molding the two resin layers 4, 6 over the (first) glass substrate 2, an adhesive 9 could be used to stack arid adhere (join) the second glass substrate 8 onto the second resin layer 6 as shown in FIG. 1F. Consequently, because the second glass substrate 8 is adhered by the adhesive 9, in the case of manufacture to a PF lens 41 in which the two resin layers 4, 6 are molded between the two glass substrates 2, 8, the need to form a primer layer on the second glass substrate 8 is obviated, and the PF lens 41 manufacturing process can be simplified.

Additionally, whereas in the embodiments mentioned above, only two resin layers are molded over the (first) glass substrate, such an arrangement is not provided by way of limitation; it would be acceptable, for example, to mold three or more layers, applying the present invention during stacking and molding of each layer of the plurality of layers on the base material. In this case, the viscosity of the resin material employed during molding of at least any one of the plurality of layers can be one having a viscosity of 3000 mPa·s to 7000 mPa·s. The viscosity of the resin can be 4600 mPa·s to 5400 mPa·s.

In the embodiments mentioned above, a glass substrate is employed as the base material, but such an arrangement is not provided by way of limitation; a substrate of plastic or the like, for example, could also foe employed, as long as the material is transparent.

In the embodiments mentioned above, the glass substrate, the first resin layer, and the second layer are each molded to disk shape, but such an arrangement is not provided by way of limitation; at least any one face (the first or other face) of the glass substrate, the first resin layer, and the second resin layer may be a spherical face or an aspherical face. Additionally, after the first resin layer and the second resin layer have been formed on the glass substrate, the external circumferential parts may be cut to effect finishing the desired shape. In a case in which the second resin layer has an aspherical face, the thickness of the second resin layer can be from 50 μm to 1000 μm.

While the embodiments mentioned above describe the example of a PF lens, which is a type of diffractive optical element, such an arrangement is not provided by way of limitation; the invention is applicable sis well to ordinary Fresnel lenses, aspherical lenses, microlens arrays, and the like.

1: PF lens (first embodiment)

2; glass substrate (base material)

4: first resin layer

5: diffraction grating

6: second resin layer

21: PF lens (second embodiment)

22: first glass substrate (base material)

24: first resin layer

25: diffraction grating

26: second resin layer

41: PF lens (modification)