Abstract
The present invention relates to an optical light guide element having a first end section with a light entrance area designed for facing a light source and having a second end section with a light exit area designed for facing a light target area, wherein the light exit area is defined by a second surface area on the optical light guide element which faces a light target area, and wherein the light entrance area is defined by a first surface area on the optical light guide element which faces the light source, wherein the first end section comprises a first inclined surface area which forms an acute angle with the first surface area of the light entrance area, wherein the second end section forms a second inclined surface area which encloses an acute angle with the surface area of the light exit area, characterized in that said first surface area on the optical light guide element which faces the light source comprises a first replicated polymer lens.
Claims
1. An optical light guide element having a first end section with a light entrance area designed for facing a light source and having a second end section with a light exit area designed for facing a light target area, wherein the light exit area is defined by a second surface area on the optical light guide element which faces a light target area, and wherein the light entrance area is defined by a first surface area on the optical light guide element which faces the light source, wherein the first end section comprises a first inclined surface area which forms an acute angle with the first surface area of the light entrance area, wherein the second end section forms a second inclined surface area which encloses an acute angle with the surface area of the light exit area, characterized in that said first surface area on the optical light guide element which faces the light source comprises a first replicated polymer lens, said first inclined surface area and said second inclined surface area both comprise a substrate provided with a reflective surface.
2. An optical light guide element according to claim 1, wherein said second surface area on the optical light guide element which faces a light target area comprises a second replicated polymer lens.
3. An optical light guide element according to claim 1, wherein in the main direction of light propagation within the optical light guide element one or more optical elements are positioned, wherein said optical elements are chosen from the group of lenses, infra red filter, diaphragm, aperture, beam splitter, polarizer and dichroic filter.
4. An optical light guide element according to claim 1, wherein said first replicated lens is of the concave or convex shape.
5. An optical light guide element according to claim 2, wherein said second replicated lens is of the concave or convex shape.
6. An optical light guide element according to claim 1, wherein said second surface on the optical light guide element comprises one or more grating elements.
7. An optical light guide element according to claim 1, wherein said substrate of said first inclined surface area comprises glass.
8. An optical light guide element according to claim 1, wherein said substrate of said second inclined surface area comprises a glass.
9. An optical light guide element according to any claim 1, wherein the volume between said first end section and said second end section comprises a cured transparent polymer.
10. An optical light guide element according to claim 2, wherein the material for the first replicated polymer lens and the second replicated polymer lens are the same.
11. An optical light guide element according to claim 2, wherein the material for the first and second replicated polymer lens differs from the cured transparent polymer material used for the volume between said first end section and said second end section.
12. An optical light guide element according to claim 1, wherein said first and/or second surface comprises a cured polymer.
13. An optical light guide element according to any claim 1, further comprising at least one beam splitter positioned in the main direction of light propagation within the optical light guide element, at least one grating element positioned on said second surface where a light exit area is defined, wherein light diffracted by said at least one beam splitter is passed through said at least one grating element.
14. An optical light guide element according to claim 13, further comprising a plurality of beam splitters positioned one after another in the main direction of light propagation within the optical light guide element, a plurality of grating elements positioned on said second surface where a light exit area is defined, wherein light diffracted by said plurality of beam splitters is passed through said plurality of grating elements, respectively.
15. A method for manufacturing an optical light guide element according to any one or more of the preceding claims, the method comprising the steps of: i) providing a first mould provided with a first mould surface having a plurality of lens shapes and recesses; ii) providing a first liquid curable polymer on top of said first mould surface of said first mould; iii) providing a second mould provided with a second mould surface having a plurality of ribs; iv) contacting said first mould with said second mould such that the first liquid curable polymer spreads into the plurality of lens shapes and recesses and that said ribs of said second mould fit into said recesses of said first mould; v) curing said first liquid curable polymer for obtaining a first mould provided with a layer of cured first polymer, and removing said second mould; vi) positioning a plurality of optical elements into said recesses of said first mould provided with a layer of cured first polymer; vii) providing a second liquid curable polymer in the area between said positioned optical elements; viii) curing said second liquid curable polymer; ix) providing a third liquid curable polymer on top of said layer of cured second polymer; x) contacting said third liquid curable polymer with a third mould provided with a third mould surface having a plurality of lens shapes and recesses; xi) curing said third liquid curable polymer and removing said first and third mould for obtaining an array of optical light guide elements; and xii) singulating said array of optical light guide elements.
16. A method according to claim 15, wherein before contacting said third liquid curable polymer with said third mould an additional step is carried out, namely the preparation of such a third mould, comprising providing a third mould provided with a third mould surface having a plurality of lens shapes and recesses, providing a fourth liquid curable polymer on top of said third mould surface of said third mould, providing a second mould provided with a second mould surface having a plurality of ribs, and contacting said third mould with said second mould such that the fourth liquid curable polymer spreads into the plurality of lens shapes and recesses and that said ribs of said second mould fit into said recesses of said third mould, and removing said second mould.
17. A method according to claim 15, wherein between step iii) and iv) an additional step is carried, namely a step of placing a foil between said second mould surface having a plurality of ribs of said second mould and said first liquid curable polymer on top of said first mould surface of said first mould.
18. A method according to claim 15, wherein step vi) further comprises positioning one or more optical elements onto said layer of cured first polymer between said plurality of optical light guide elements, wherein said one or more optical elements are chosen from the group of lenses, infra red filter, diaphragm, aperture, beam splitter, polarizer and dichroic filter.
19. A method according to claim 15, wherein step vii) further comprises the gradual provision of said second liquid curable polymer in the area between said positioned optical elements, wherein the gradual provision preferably comprises the application of a layer of second liquid curable polymer and partially curing said second polymer and the application of one or more additional layers of second liquid curable polymer and partially curing the same.
Description
[0055] Various aspects of the present invention are illustrated by way of example, and not by way of limitation, in the accompanying drawings, wherein:
[0056] FIG. 1 shows a step of the present method for manufacturing an optical light guide element;
[0057] FIG. 2 shows another step of the present method for manufacturing an optical light guide element;
[0058] FIG. 3 shows a step of the present method for manufacturing an optical light guide element;
[0059] FIG. 4 shows another step of the present method for manufacturing an optical light guide element;
[0060] FIG. 5 shows another step of the present method for manufacturing an optical light guide element;
[0061] FIG. 6 shows another step of the present method for manufacturing an optical light guide element;
[0062] FIG. 7 shows another step of the present method for manufacturing an optical light guide element;
[0063] FIG. 8 shows another step of the present method for manufacturing an optical light guide element;
[0064] FIG. 9 shows another step of the present method for manufacturing an optical light guide element;
[0065] FIG. 10 shows another step of the present method for manufacturing an optical light guide element;
[0066] FIG. 11 shows another step of the present method for manufacturing an optical light guide element;
[0067] FIG. 12 shows another step of the present method for manufacturing an optical light guide element;
[0068] FIG. 13 shows another step of the present method for manufacturing an optical light guide element;
[0069] FIG. 14 shows another step of the present method for manufacturing an optical light guide element;
[0070] FIG. 15 shows another step of the present method for manufacturing an optical light guide element;
[0071] FIG. 16 shows another step of the present method for manufacturing an optical light guide element.
[0072] The identical parts are provided with the same reference symbols in the figures.
[0073] The first step of the present method for manufacturing an optical light guide element can be seen as a step of pre-fill mould with lens and positioning features. FIG. 1 shows a first mould 1 provided with a first mould surface 4 having a plurality of lens shapes 3 and recesses 5. These lens shapes can have different shapes, such as concave and convex. The mould 1 is not restricted to a specific shape of lens 3. In a first step a first liquid curable polymer 6 is applied on top of first mould surface 4 of first mould 1. In a next step a second mould 2 provided with a second mould surface 87 having a plurality of ribs 88 is brought into contact with the first mould 1. Mould 2 is transparent to light and the first liquid curable polymer 6 is cured by energy 8, for example UV curing, electron beam curing and thermal curing. The step of contacting is carried out such that the first liquid curable polymer 6 spreads into the plurality of lens shapes 3 and recesses 5 and those ribs of second mould 2 fit into recesses 5 of first mould 1. After the step of curing the first liquid curable polymer 6 first mould 1 is provided with a layer of cured first polymer. The second mould 2 can now be removed without damaging the layer of cured first polymer. FIG. 1. also shows the application of a foil 89. The application of such a foil encompasses a preferred embodiment because several polymerization processes will result in more even polymer constructions when using such a foil 89.
[0074] FIG. 2 shows a step of manufacturing reflective elements. A substrate 1 for example made of glass, is provided on each side with a reflective coating 12, 13. FIG. 2 also shows dicing lines 14 for obtaining individual reflective elements, i.e. optical mirror elements (see FIG. 3).
[0075] FIG. 3 shows the positioning of optical features, such as optical mirror elements 15, for example manufactured according to FIG. 2. According to FIG. 3 a plurality of optical mirror elements 15 is positioned into the recesses 5 of first mould 1 provided with a layer of cured first polymer 9. Although recesses 5 show a rectangular shape, different shapes and angles are possible. FIG. 3 also shows the positioning of an optical element 17 on top of the layer of cured first polymer 9. The number and function of optical elements 17 is not restricted and the optical element can be chosen from the group of lenses, infra red filter, diaphragm, aperture, beam splitter and XX, or a combination thereof.
[0076] A next step, as shown in FIG. 4, is the provision of a second liquid curable polymer 18, 19, 20 in the area between the optical mirror elements 15 and optical elements 15, as discussed before. As shown here, the second liquid curable polymer 18, 19, 20 is provided as a three layer polymer, wherein in a first step second liquid curable polymer 18 is applied and cured (via energy 8), followed by the application of second liquid curable polymer 19. This second liquid curable polymer 19 is subsequently cured and another second liquid curable polymer 20 is applied and cured. The present method is not restricted to any specific number of layers of second liquid curable polymer but, from the viewpoint of shrinkage, it is preferred to apply second liquid curable polymer in at least two layers with intermediate curing. In addition it is also preferred to under cure, i.e. not fully cure, the second liquid curable polymer for preventing the formation of interfaces between the individual layers of second liquid curable polymer. The result of the application of second liquid curable polymer is that the optical elements, i.e. the optical mirror elements 15 and the optical element 17, are embedded by the second cured polymer.
[0077] A next step, as shown in FIG. 5, relates to the application of a providing a third liquid curable polymer 21 on top of the layer of cured second polymer. FIG. 5 clearly shows that optical mirror elements 15 and the optical element 17 are fixed on the first layer of cured polymer 9 and embedded by the second cured polymer. FIG. 5 also shows a third mould 23 provided with recesses 24 and lenses 25, wherein both the recesses 24 and lenses 25 are provided with a layer of cured polymer 27. The third mould 23 is brought into contact (see the direction of movement, i.e. arrows 22) with the layer of third liquid curable polymer 21. The third liquid curable polymer 21 will flow into the recesses 24 of third mould 23. The shape and angle of recesses 24 of third mould 23 will match with the shape and angle of optical mirror elements 15 of first mould 1.
[0078] In FIG. 6 the third liquid curable polymer 21 is spread by pressing third mould 23 onto first mould 1 and subsequently cured by energy 8. The result is the formation of a layer of third cured polymer 21.
[0079] FIG. 7 shows the situation in which both mould 1 and mould 23 have been removed resulting in an array of optical light guide elements 30.
[0080] The excess or superfluous parts of optical mirror elements 15 can be removed by mechanical means, such as a dicing blade, resulting in the array of optical light guide elements having flat surfaces 46, as shown in FIG. 8A. FIG. 8A also shows a dicing blade 32 for singulating along dicing lines 31 of the array of optical light guide elements into individual optical light guide elements 40 (see FIG. 8B) and 4 (see FIG. 8C). Optical light guide element 40 (see FIG. 8B) comprises two optical mirror elements 15, lens 3 made of cured polymer 9, second cured polymer 18, 19, 20, cured polymer 21, lens 25 made of cured polymer 27. Optical light guide element 41 (see FIG. 8C) differs from optical light guide element 40 in the presence of optical element 17 in the area comprising second cured polymer 18, 19, 20. In another embodiment it is possible to further cut optical light guide element 40 into two complementary optical light guide elements by dicing through a dicing line (not shown) located in optical element 17, i.e. perpendicular to the outer surfaces where lenses 3, 25 are positioned. This embodiment will be further discussed in FIGS. 9A, 9B and 9C.
[0081] FIG. 9A shows another way of singulating along dicing lines 31 of the array of optical light guide elements into individual optical light guide elements 42 (see FIG. 9B) and 43 (see FIG. 9C). The dicing blade (see FIG. 9A) creates a cut through optical element 17 as shown in FIG. 9A thereby forming two optical light guide elements 42, 43. Optical light guide element 42 (see FIG. 9B) comprises one optical mirror element 15, a flat surface 46, second cured polymer 18, 19, 20, cured polymer 21, lens 25 made of cured polymer 27, and optical element 17, wherein optical element 17 comprises a smooth optical surface 44 recessed from dicing line and a rough dicing surface 45. Optical light guide element 43 (see FIG. 9C) comprises one optical mirror element 15, a flat surface 46, second cured polymer 18, 19, 20, cured polymer 21, lens 3 made of cured polymer 9, and optical element 17, wherein optical element 17 comprises a smooth optical surface 44 recessed from dicing line and a rough dicing surface 45. Such an optical light guide element 43 and optical light guide element 42 can be regarded as “two halves” of the optical light guide element 41 shown in FIG. 8C. Such an optical light guide element 41 comprises two inclined surface areas 15, i.e. one at the light entrance area and on at the light exit area, whereas optical light guide elements 42, 43 only comprise one inclined surface area, wherein the optical element 17 is perpendicular positioned to the lens 25, 3, respectively. Such optical light guide elements 42, 43 are compact elements.
[0082] FIG. 10A shows an additional step in the method for manufacturing an optical light guide element, namely the XY reinforcement by positioning an additional substrate layer 47 on both sides of the array of optical light guide elements. An example of such a substrate layer 47 is bonded glass or FR4 substrate with regular spaces holes or openings. The array of optical light guide elements as shown in FIG. 10A can be diced into individual optical light guide elements 48 as shown in FIG. 10B.
[0083] The XY reinforcement (see FIG. 11A) can be further improved by introducing liquid curable polymer into the openings or holes present in the substrate layer 47. After curing of this polymer 49 one or more lenses 51 can be replicated on top of the polymer layer 49. These lenses 51 are made of cured polymer 52. The array of optical light guide elements as shown in FIG. 11A can be diced into individual optical light guide elements 60 as shown in FIG. 11B.
[0084] According to another embodiment the XY reinforcement can be further improved by the positioning of a glass wafer 72 on both sides of the array of optical light guide elements, and subsequently singulating the array thus manufactured into individual optical light guide elements 70 as shown in FIG. 12. Such a glass wafer may be bonded to the array of optical light guide elements by a bonding layer 71. In addition, the glass wafer 72 may comprise replicated features, such as lenses 73.
[0085] According to another preferred embodiment of the method for manufacturing an optical light guide element it is possible to replace the layers of second cured polymer 75 for a material that can be removed after completion of the manufacturing method. This means that in the optical light guide element as shown in FIG. 13, comprising cured polymer 75 located between wafer 72 and mirror elements 15, the cured polymer 75 is to be replaced during its manufacturing process by another type of material, such that material 75 can be removed, for example by dissolution or etching without damaging the interior optical surfaces of the optical element. The result of the removal of material 75 from the optical light guide element (shown in FIG. 13A) is the presence of air, indicated by reference number 74, as shown in FIG. 13B.
[0086] According to another embodiment it is preferred to use non-flat reflective surfaces (see FIG. 14A). FIG. 14A shows an embodiment in which a flat substrate is replaced for a substrate with replicated features enabling the creation of different types of reflective surfaces. In FIG. 14A a glass substrate 11 is provided on both sides with replicated lenses 81, 83. These replicated lenses 81, 83 may be provided with one or more coatings 82, 84, such as reflective coatings. The substrate shown in FIG. 14A can be diced along specific dicing lines for obtaining individual reflective elements, i.e. optical mirror elements 15. Analogy to the method as disclosed here for FIG. 3 these curved optical mirror elements 5 may replace one or more of the optical mirror elements as shown in any of the previous figures shown here. FIG. 14B shows an optical light guide element 80 comprising concave mirrors resulting from replicated lenses 81, 83, lenses 86, 85, optical element 17 embedded in cured polymer.
[0087] FIG. 15A, 15B, 15C show three examples wherein mirror surfaces are placed at different angles. FIG. 15A shows incoming light ray 105, outcoming light ray 106 and the main direction of light propagation within the optical light guide element 100. Mirror surfaces 101, 102 are placed such that light ray 105 enters the top of the optical light guide element 100 and leaves it at the underside thereof. In the optical light guide element 110 as shown in FIG. 15B mirror surfaces 101, 103 are placed such that light ray 105 enters the top of the optical light guide element 100 and leaves it at the top as well. In the optical light guide element 120 as shown in FIG. 15C mirror surfaces 101, 104 are placed such that light ray 105 enters the top of the optical light guide element and leaves it at the front side thereof.
[0088] FIG. 16. shows a specific embodiment of an optical light guide element according to the present invention, i.e. spectrum analyser 90. Incoming light 94 enters the optical light guide element 90 at the top and is reflected by optical mirror 15. The light propagates within the optical light guide element through three beam splitters 91, 92, 93 and a part of the light is reflected on optical mirror 15. In each beam splitter 91, 92, 93 a part of the incoming light is reflected and directed, via gratings 96, 97, 98, respectively, onto a detector 95. According to such a specific embodiment of the present optical light guide element it is possible to divide the incoming light 94 into different parts.
