Optically transparent component with two sets of cells

Detailed description of the invention

The present invention relates to a light transmissive member having two sets of cells, a multi-layer structure suitable for use in the manufacture of the member, and a method for processing the member and the structure.

In particular, International Patent Publication WO2006 / 013250 describes the manufacture of an optical member having the shape of a base member having a set of parallel cells on one of its surfaces. The member structure is often referred to as a pixel structure. The cell contains one or more optically active substances, which impart some particular optical properties to the optical member. The above-mentioned method for manufacturing an optical member is particularly suitable because an optical member having different optical characteristics can be obtained by changing the active substance introduced into the cell.

Further, it is well known to manufacture an optical member containing a plurality of sets of cells arranged in each overlapping layer on the surface of the base optical member. Further, the optical member has an optical characteristic that is a combination of the optical characteristics provided by all the sets of cells.

However, the transparency of the optics may be inadequate for certain applications, especially ocular applications. The walls separating the cells in the set diffract the light. This diffraction itself causes macroscopic diffusion.

In the present invention, the optical member is transparent when the image observed through the optical member is perceived without significant reduction in contrast. In other words, the interposition of the transmissive optical member between the image and the observer of the image does not significantly reduce the quality of the image. In particular, diffraction refers to the following phenomenon. That is, when the light is physically restricted, the light to be observed is scattered ([Optics, foundations and applications], 7th edition, DUNOD, October 2004, p. 262). Due to the diffraction caused by the walls of the optics with the cells, the spots of light are no longer perceived when viewed through the optics. The resulting macroscopic diffusion, or incoherent diffusion, produces a milky white appearance, or diffusion halo, due to the pixel structure of the optics. This causes the contrast in the image observed through the optics to be lost. This loss of contrast is comparable to the loss of transparency, as defined above.

Therefore, it is an object of the present invention to propose a new type of optical member with a cell that has a higher level of transparency.

For the above purposes, the present invention proposes a light transmissive member including a base optical member and two sets of transmissive cells. The cells in the two sets are arranged in separate layers. The layer is overlaid on the surface of the base member. Each cell contains an optically active material, and the cells in each set are separated from each other by a separation in a corresponding layer provided parallel to the surface of the base member. In addition, the cells in one set are arranged along an axis perpendicular to the surface of the base member so as to line up with the separators belonging to the layer of cells in the other set. In addition, each contour of the cell and each contour of the separators placed alongside each other has substantially the same projection on the surface of the base member.

In other words, in the present invention, the two sets of cells have a cell pattern that is complementary to the surface of the optical member. In addition, within each layer, cells and separators are alternately arranged in all directions parallel to the surface of the member so that two adjacent cells are always separated from each other.

In the optical member of the present invention, a light beam passing through the member substantially perpendicular to the layer is inevitably one cell and one regardless of the point of impact of the light beam on the surface of the optical member. It passes through two separations. The only thing that changes depending on the irradiation point is the order of cells and separations on the path of the light beam. Therefore, all of the predetermined rays have substantially homogeneous optical paths through the optics. Therefore, almost no deformation occurs in the image observed through the member. In other words, in the above defined sense, the member is relatively transparent.

Since the light paths passing through the optical member are homogeneous at different positions on the surface having each set of cells, it is not necessary for the separation portion and the active substance contained in the cells to have the same refractive index. By eliminating such index matching constraints, the same cell substrate can be used for different optics. These optics differ with respect to the active material introduced into each cell in the member. The base optical member and each set of cells can be mass-produced at low cost.

In addition, in the optical member of the present invention, the separation between cells has an area equivalent to the area of the cells (dimension) parallel to the surface of the substrate. Therefore, the separator does not cause diffraction at the additional scale. For the above reason, the transparency of the member is also improved as a result.

Further, since the area of the cell and the area of the separated portion are equal to or the same, it is possible to prepare both sets of cells by using a well-known lithography method in particular.

Finally, if the cell in at least one of the sets is closed by an outer membrane attached onto the set, the membrane can be easily fixed onto the separation in the cell, such as with an adhesive. it can. The cell can be tightly sealed in view of the fact that the separator indicates each region that is large and available for membrane fixation.

In particular, the optical member of the present invention may form an optical lens, particularly an ocular lens. At any time, the optical member may constitute a component of the optical device for measurement or aiming, a lens for goggles, in particular a helmet visor or peephole for sports or protective purposes.

The present invention also provides a layered transmissive cell structure that can be applied on the base optical member to provide a pixel member with two layers of cells as described above.

The present invention also provides a method for manufacturing the structure. The method is a) In turn, a step of obtaining a transmissive structure of a layered layer comprising a lithography resin, an additional layer that absorbs radiation from a lithographic method suitable for etching the first layer of the resin, and a second layer; b) A step of forming a mask on the second layer that defines the cell formation position; c) The step of selectively removing the second layer portion and the additional layer portion and forming the first set of cells in the second layer and the additional layer as specified by the mask; d) The step of filling the first set of cells with at least one optically active substance; e) After removing the mask, it is selectively placed in line with the cells in the first set, with respect to part of the first layer that is selectively placed in line with the rest of the additional layer. The step of irradiating the first layer of the lithography resin through the second layer and the additional layer so that a part of the first layer is fixed so as not to be removed; f) The step of developing the first resin layer so as to form a second set of cells in the first resin layer; and g) It has a step of filling the cells in the second set with an optically active substance.

By using this method, two sets of cells are automatically obtained, self-aligning and complementary to each other, requiring the use of only one mask. Therefore, no special alignment step is required to obtain two overlapping layers with cells in one of the sets that are arranged exactly in line with the separator between the cells of the other set. In addition, the cells and separators arranged to cover the other automatically have contours that are identical and parallel to the layered structure.

Finally, the present invention provides a method of manufacturing an optical member in which the above-mentioned layered cell structure is fitted on a base optical member. The resulting optical member may be an optical lens and, in particular, an ocular lens.

Other features and advantages of the present invention are shown with reference to the accompanying drawings, using the following embodiments without limitation. FIG. 1 is a cross-sectional view of the cell structure of the present invention. 2a to 2c are plan views of the present invention according to FIG. FIGS. 3a-3f show continuous steps in the method of manufacturing a cell structure according to the above drawings. FIG. 4 shows the manufacture of the optical member of the present invention. FIG. 5 is a cross-sectional view showing a modified form of the cell structure of the present invention.

The dimensions of the illustrated elements are intended to be clearly illustrated and are not actual dimensional proportions or actual dimensional proportions. Moreover, when the same member numbers are used in different drawings, they correspond to the same components or components that perform the same function.

With reference to FIGS. 1 and 2a-2c, the present specification begins with the cell structure of the present invention.

Structure 100 comprises two sets of cells 1. The two sets of cells 1 are arranged in two layers 10 and 20, respectively, corresponding to each set of cells. Layers 10 and 20 are stacked inside structure 100 along an axis N perpendicular to the outer surface of structure 100. The outer surface of structure 100 is S₁And S₂And. Cells 1 in a particular set, i.e. cells 1 placed within a particular layer 10 or 20, are separated from each other by a separator 2.

In addition, the cell 1 belonging to the set of cells in the layer 10 is arranged along the axis N in a row with the separating portion 2 belonging to the layer 20. Conversely, the cell 1 belonging to the set of cells in the layer 20 is arranged side by side with the separation unit 2 belonging to the layer 10. Further, the cell 1 and the separation portion 2 arranged side by side with each other have each contour, and each contour has a surface S.₁And S₂It has substantially the same projection on a plane parallel to.

Since the contours of the cells in the two sets match, cell 1 in layer 10 forms a pattern that complements the pattern of cell 1 in layer 20. The pattern of cells in each set may be triangular (FIG. 2a), square (FIG. 2b), rectangle, or random (FIG. 2c). The length of the side surface of the cell 1 parallel to the structure 100 is also the length of the side surface of the separation part 2 and may be in the range of 1 micrometer (μm) to 200 μm, preferably 5 μm to 100 μm. It may be a range. Each cell 1 or separation 2 is not individually visible to the naked eye and does not cause light diffusion. In FIG. 1, the length of this side surface is d.

Both sets of cells inside layers 10 and 20 preferably have substantially the same filling factor, respectively. The term "filling factor", when applied to a set of cells, is used to refer to the percentage of the area of structure 100 occupied by cell 1 in a set within a particular layer 10 or 20. .. Given that the patterns in the two sets of cells are complementary, the two filling rates are substantially equal to 50%.

Each cell 1 contains an optically active substance. The active substance may include a refracting substance, a polarizing substance, an absorbing substance, a coloring substance, a filter material, an electrically active substance, and the like. The material is selected by conventional methods depending on the function of the optical properties to be imparted to the optical member into which the cell structure 100 is integrated. For example, the refracting material may be introduced into the cell 11 which has a different light refractive index between the cells which are offset in the direction parallel to the structure 100. Therefore, the structure 100 can provide a default light output expressed in terms of diopter. Furthermore, in the context of the present invention, an electrically active substance refers to a substance having properties that can change in response to an electrical control signal.

The active substance contained in at least one of cell 1 may be a liquid or a gel. Under such circumstances, either of the two outer coatings 4 and 5 in structure 100<u style="single">Face</u>It can be placed on top and can seal cell 1 in layers 10 and 20. Such a method prevents the active substances contained in the various cells 1 from being mixed or leaking from the structure 100. The coatings 4 and 5 may be adhered to the separation portion 2 in the corresponding layers 10 and 20 by, for example, layers of adhesive (PSA) materials 6 and 7. Also, at any time, for example, when the active substance contained in cell 1 of layers 10 and 20 is cross-linked after being introduced into the cell, a single outer coating is not present in structure 100.<u style="single">The side of the gap</u>It may be placed only on top.

Structure 100 also includes an interlayer film 3 arranged between layers 10 and 20. The film 3 can impart stronger adhesiveness to the structure 100, making the structure easier to operate.

The structure 100 is made of a material that is transparent, so that the structure 100 itself is transparent and light can pass between the two outer surfaces of the structure 100. In particular, the separating portion 2 in at least one of the two layers 10 and 20 may be made of a resin, and the membranes 3 to 5 may be made of polycarbonate (PC), polyethylene (PE), polyimide, or polyethylene. It may be based on terephthalate (PET). The films 3 to 5 may have a thickness in the range of 2 μm to 50 μm on the axis N, respectively, and the layers 10 and 20 may have a thickness in the range of 5 μm to 500 μm, respectively. In FIG. 1, the thicknesses of layers 10 and 20 are e, respectively.₁And e₂It is expressed as.

Subsequently, a method for obtaining the layered cell structure will be described with reference to FIGS. 3a to 3f.

First, the structure 100, in order along the upward axis N in FIG. 3, is a layer 10 of the lithography resin, an additional layer 21 of a resin that absorbs lithography radiation that can be used to etch the layer 10, and The other resin layer 22 is provided. Both layers 21 and 22 form layer 20 as described above. Layers 10, 21, and 22 are initially homogeneous and they exhibit a uniform thickness. For example, the thickness e21 of the layer 21 is in the range of 10 μm to 200 μm, and the thickness e22 of the layer 22 is in the range of 10 μm to 400 μm. The structure 100 initially has an interlayer film 3 placed between layers 10 and 20 at any time, and / or layer 10 on the opposite side of layer 22.<u style="single">Face</u>It may include a support film 8 arranged on top. When interlayer film 3 is in structure 100, interlayer film 3 allows the radiation used to etch layer 10 during lithography to pass through.

Then, the mask 30 is formed on the layer 22. One possibility is that the mask 30 may be formed by a lithography method. The mask 30 has an opening O, and the layer 22 and the layer 21 are etched by removing the portion that has passed through the opening O. In this way, a first set of cells 1 corresponding to the opening O in the mask 30 is formed in layers 21 and 22.

Mask 30 takes into account the covering factor on the surface S2 of structure 100. The coverage corresponds to the desired filling rate for cell 1 in layer 20. Preferably, the coverage is approximately equal to 50%. As a result, the surface fraction is finally occupied by the cell 1 which is balancedly allocated between the layers 10 and 20.

Similarly, the mask 30 takes into account the opening of the pattern corresponding to the cell pattern suitable for layer 20. In particular, the opening O may exhibit a triangular, square, rectangular, or random pattern.

Two different methods may be used to etch layers 21 and 22.

In the first method, at least layer 22 is composed of a lithographic resin and is etched using a suitable lithographic method. Therefore, radiation F1 (FIG. 3b) is directed toward layer 22 through the opening O in the mask 30 in the opposite direction to the N axis. Radiation F1 may be ultraviolet or electron beam. The rest of the mask 30 absorbs radiation F1 so that only the uncoated portion of layer 22 is irradiated. Upon irradiation, the resin in layer 22 is polymerized or crosslinked, and the above portion is non-removably fixed.

Remove the rest of the mask 30 . At that time, layer 22 is developed. That is, the unirradiated portion is removed (Fig. 3c). In other words, layer 22 is a negative resin. It is well known that the layer 22 is developed with a lithography resin, and this can be performed by contacting the layer 22 with a solution for dissolving the non-polymerized resin. For example, since the same lithographic resin used for layer 22 is a component of the material of layer 21, a portion of layer 21 arranged side by side with the portion removed from layer 22 can be removed at the same time. Alternatively, the layer 21 may simply be dissolved in contact with a suitable solution at some location in the removed layer 22.

In a second method (not shown), the uncoated portion of layer 22 can be removed by etching with an ion beam. This technique, called reactive ion etching (RIE), is well known to those of skill in the art. To perform the above treatment, the surface S of structure 100 is provided by an ion beam having sufficient energy to grind the resin in the opening region of the mask 30.₂To scan. Layer 21 may be etched simultaneously with an ion beam at any time.

The remaining portion 22a of layer 22 and the remaining portion 21a of layer 21 in FIG. 3c form a separation portion 2 in layer 20, and the empty portion in layers 21 and 22 constitutes cell 1.

Then, one or more arbitrary active substances are introduced into cell 1 in layer 2 to fill cell 1 (Fig. 3d). When the active substance is a liquid or gel, the active substance can be injected into cell 1 using a spray head such as an inkjet printer type. The head is surface S₂It works when it moves above the cell and faces the cell so that the active substance can be sprayed into it. The method of filling cells in this way is particularly fast and inexpensive because it can be programmed and is compatible with the use of multiple active substances for a predetermined cell structure. In addition, a plurality of active substances can be mixed in a predetermined cell by introducing an appropriate amount of each substance into the cell using nozzles having different heads. The nozzle is connected to a container for each active substance.

At any time, the membrane 5 provided on the open surface of the separation portion 2 can be used to seal the cell 1 filled with the active substance in the layer 20. For example, film 5 is covered with layer 7 of PSA material and the surface S of structure 100 with layer 7 facing layer 20.₂You may press it against. Alternatively, another adhesive material may be used for layer 7.

Then surface S₂The layer of the lithography resin 10 is irradiated through and passed through the layer of the cell 20 (Fig. 3e). Therefore, a portion of layer 10 arranged in line with cell 1 of layer 20 is non-removably fixed and selectively aligned with the remaining parts 21a and 22a of layers 1 and 22. Comparable to part of the placed layer 10. Therefore, radiation F which can be ultraviolet or electron beam₂Is the surface S of the structure parallel to and in the opposite direction to the axis N₂Directed against. The remaining part 21a of layer 21 is radiation F₂Since it functions as a mask by absorbing the above, only the portion of layer 10 arranged in line with cell 1 in layer 20 is irradiated. For the above purposes, membranes 3 and 5 are radiation F₂To be transparent.

Structure 100 is its surface S₁When the support film 8 is provided on the top, the support film 8 is removed by a method such as peeling off (Fig. 3f).

Layer 10 is made of a negative lithography resin and is, in some cases, identical to the lithography resin of layer 22. Develop and remove only the unirradiated areas. In this way, the separation part 2 is also formed in the layer 10 side by side with the cell 1 in the layer 20. These separators 2 in layer 10 define cell 1 in layer 10. That is, the contour of the cell 1 in the layer 10 coincides with the contour of the separation portion 2 and the contour of the cell 1 in the layer 20. Thus, the two layers 10 and 20 include each set of cells 1 that are complementarily arranged.

Finally, cell 1 of layer 10 is filled with the optically active material using a method similar to that already used for cell 1 in layer 20. From time to time, as the next step, the surface S of structure 100₁The filled cell 1 in layer 10 may be sealed by affixing a second outer membrane on top. Preferably, during the last two steps, the structure 100 is turned inside out so that cell 1 of layer 10 is open upwards. The structure 100 has the form shown in FIG.

The cell structure 100 presented by the present invention can be used to manufacture optical members, especially ocular lenses. For the above purpose, first, a base optical member 200 (FIG. 4) that serves as a substrate is provided. The base member 200 itself may be an optical lens or an ocular lens. The term "ophthalmic lens" refers to a lens designed to fit into a pair of eyeglass frames. The lens may be obtained before it is cut to the frame dimensions of the frame. This constitutes an eye lens as a material. Alternatively, the ophthalmic lens may be cut to the size of the frame. The structure 100 is the surface S of the base member 200.₂₀₀It is fitted on one of the surfaces and the surface S₂₀₀It is processed to the same curvature as. For the above purposes, structure 100 is carefully deformed using methods that are well known per se, to avoid crushing or breaking cell 1 or separation 2 in any of layers 10 and 20. Then, the structure 100 is attached to the surface S of the base member 200 by an adhesive or the like.₂₀₀Fix it on top.

The optical member with the cell obtained by the above method reduces the diffraction of light rays passing through the optical member. In other words, the initial intensity of the beam, i.e. its intensity before passing through the member, should be almost completely zero-order diffraction after passing through the member. In particular, the optical member of the present invention is configured such that a part of the energy of the incident light beam exceeding 95% is included in the zero-order diffraction. At this time, the incident direction is perpendicular to the surface of the member. In addition, this diffraction is substantially constant when the two layers 10 and 20 have the same thickness, which are different at the same time.

In addition, the member exhibits a very small chromatic effect. In particular, there is virtually no pearly luster on the member, even when viewed at different angles of incidence. Therefore, the above members are suitable for a wide variety of applications, and are particularly suitable for applications with particularly strict appearance requirements such as eye applications.

As a matter of course, a wide variety of uses of the present invention can be introduced as compared with the above-described embodiments. In particular, structure 100 has a surface S₁Or S₂There may be a functional coating on at least one of the above, specifically one of the exposed surfaces of the final optics. The functional coating can be carried out using the outer membrane 4 or 5. These include, in particular, anti-shock coatings, anti-reflective coatings, anti-scratch coatings, antifouling coatings, or some combination of such coatings.

In addition, in the initial stage, a resin layer 22 etched with a positive resin may be formed instead. Under such circumstances, cell 1 of layer 20 is formed at the position of the opening O in the mask 30.

As shown in FIG. 5, in the modification of the embodiment of the present invention, the first cell 1 and the first separation portion 2 adjacent to each other in one of the layers 10 and 20 are oblique to the axis N. Contact surface I₁May be indicated. The second cell and the second separation part, both of which are connected to each other and belong to the other layer, are arranged side by side with the first separation part and the first cell, respectively. The second cell and the second separation part have a contact surface I.₁Contact surface I that inclines in the opposite direction to₂Have. In other words, at the two contact surfaces, the angle α with respect to the axis N₁₀And angle α₂₀Have the same absolute value and are opposite. The cell structure also results in reduced diffraction. Light passing through structure 100 parallel to axis N is the contact surface I.₁And I₂This is because it has the same path of passing through the active substance and the substance consisting of the separation part regardless of the deviation of the light ray with respect to (the light ray R in FIG. 5).₁~ R₄See).

Ultimately, the layered structure may be flexible or rigid, may be flat or curved, and may at any time be used alone as a separate optical member.

<figref num="1">It is sectional drawing of the cell structure of this invention.</figref><figref num="2a">It is a top view of this invention according to FIG.</figref><figref num="2b">It is a top view of this invention according to FIG.</figref><figref num="2c">It is a top view of this invention according to FIG.</figref><figref num="3a">It is a figure which shows the continuous step in the manufacturing method of the cell structure according to the said drawing.</figref><figref num="3b">It is a figure which shows the continuous step in the manufacturing method of the cell structure according to the said drawing.</figref><figref num="3c">It is a figure which shows the continuous step in the manufacturing method of the cell structure according to the said drawing.</figref><figref num="3d">It is a figure which shows the continuous step in the manufacturing method of the cell structure according to the said drawing.</figref><figref num="3e">It is a figure which shows the continuous step in the manufacturing method of the cell structure according to the said drawing.</figref><figref num="3f">It is a figure which shows the continuous step in the manufacturing method of the cell structure according to the said drawing.</figref><figref num="4">It is a figure which shows the manufacture of the optical member of this invention.</figref><figref num="5">It is sectional drawing which shows the modified form of the cell structure of this invention.</figref>