Low wavefront error optical filter coating

Abstract

The present invention provides an optical component, which includes: a first optical substrate, which includes a first major surface; a multilayer polymer optical film, which is arranged on the first major surface of the first optical substrate and includes a plurality of polymer layers with a total number greater than about 50; and a first optical bonding layer, which has an average thickness of less than about 0.5 microns and is arranged between the first major surface of the first optical substrate and the multilayer polymer optical film and is in physical contact with the first major surface of the first optical substrate and the multilayer polymer optical film, the first optical bonding layer bonds the first optical substrate to the multilayer polymer optical film and contains a silylated amine.

Description

Summary of the invention

[0001] In some aspects of the present specification, an optical component is provided, which includes: a first optical substrate, the first optical substrate including a first major surface; a multilayer polymer optical film, the multilayer polymer optical film is disposed on the first major surface of the first optical substrate and includes a plurality of polymer layers with a total number greater than about 50; and a first optical bonding layer, the first optical bonding layer having an average thickness of less than about 0.5 microns and disposed between and in physical contact with the first major surface of the first optical substrate and the multilayer polymer optical film, the first optical bonding layer bonding the first optical substrate to the multilayer polymer optical film and containing a silylated amine.

[0002] In some aspects of the present specification, a polarization beam splitter is provided, comprising: a multilayer polymer reflective polarizer disposed between a first optical prism and a second optical prism; an optical bonding layer that makes physical contact with the reflective polarizer and bonds the reflective polarizer to each of the first optical prism and the second optical prism, and has an average thickness of less than about 0.2 microns, wherein the first optical prism and the second optical prism cannot be separated from each other without damaging the reflective polarizer.

[0003] In some aspects of the present specification, a polarization beam splitter is provided, which includes: a multilayer polymer reflective polarizer, which is disposed between a first optical prism and a second optical prism and includes opposing first and second principal surfaces; a first optical bonding layer, which is in physical contact with the first principal surface of the reflective polarizer and bonds the first principal surface of the reflective polarizer to the first optical prism; and a second optical bonding layer, which is in physical contact with the second principal surface of the reflective polarizer and bonds the second principal surface of the reflective polarizer to the second optical prism, wherein the first optical prism and the second optical prism cannot be separated from each other without damaging the reflective polarizer, and wherein for light with a wavelength of 0.6328 microns incident on the polarization beam splitter from each of the first principal surface side and the second principal surface side of the reflective polarizer, the polarization beam splitter has a reflection root mean square wavefront error of less than about 0.5.

[0004] In some aspects of the present invention, an optical component is provided, which includes: a first optical substrate, the first optical substrate including a first major surface; an optical film, the optical film is disposed on the first major surface of the first optical substrate so that for substantially vertically incident light and for each wavelength within a predetermined wavelength range extending at least 50 nanometers, the optical film reflects at least 60% of the incident light of at least a first polarization state; and a first optical bonding layer, the first optical bonding layer having an average thickness of less than about 0.5 microns and disposed between and in physical contact with the first major surface of the first optical substrate and the optical film, the first optical bonding layer bonds the first optical substrate to the optical film and contains a silanized amine, and wherein for light with a wavelength of 0.6328 microns incident on the optical film from each major side of the optical film, the optical component has a reflective root mean square wavefront error of less than about 0.5. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] Figure 1A is a perspective view of a polarization beam splitter according to an embodiment of the present specification;

[0006] Figure 1B is a side view of a polarization beam splitter according to an embodiment of the present specification;

[0007] Figure 1C is a side view of a polarizing beam splitter in operation according to an embodiment of the present specification;

[0008] Figure 2A and Figure 2B A side view of an optical assembly according to an embodiment of the present specification is provided;

[0009] Figure 3 is a side view of an optical component having a curved surface according to an embodiment of the present specification;

[0010] Figure 4 is a side view of a multilayer polymeric optical film according to an embodiment of the present specification; and

[0011] Figure 5 is a side view of an optical lens assembly according to an embodiment of the present specification. DETAILED DESCRIPTION

[0012] In the following description, reference is made to the accompanying drawings, which form a part of the present invention and in which various embodiments are shown by way of example. The drawings are not necessarily drawn to scale. It should be understood that other embodiments may be conceived and carried out without departing from the scope or essence of the present description. Therefore, the following specific embodiments should not be considered to have a limiting meaning.

[0013] Multilayer optical films (MOFs) such as MOF reflective polarizers and optical filter films have not been widely adopted for reflective imaging optics because they traditionally exhibit relatively high wavefront errors compared to conventional reflective imaging planes (e.g., multilayer coatings or wire grid coatings made by physical vapor deposition). Existing lamination methods that may be used to apply MOFs to optical components have process challenges that do not allow them to meet industry standards. For the purposes of this specification, the reflected wavefront error is defined as the degree of deviation seen in the optical wavefront when light is reflected from the surface of an optical component compared to when it is reflected from a completely flat (i.e., planar) surface. Existing industry standards may specify that the reflected root mean square (RMS) wavefront error is less than 1 wavefront error (or even 1 / 2 wave error, 1 / 4 wave error, or 1 / 8 wave error). For the purposes of this specification, the transmitted wavefront error is defined as the deviation seen in the optical wavefront when light is transmitted through an optical component (e.g., a lens).

[0014] According to some aspects of the present specification, silane coupling agents are used to adhere optical films (e.g., reflective polarizer MOFs) directly to low wavefront optics via a nano-thick adhesive layer, thereby allowing the film to replicate the surface of the low wavefront optic component to which it is adhered. In some embodiments, an optical component (e.g., a polarizing beam splitter or an optical lens) includes: a first optical substrate (e.g., a window, a lens, or a prism) comprising a first major surface; a multilayer polymeric optical film disposed on the first major surface of the first optical substrate; and a first optical adhesive layer disposed between and in physical contact with the first major surface of the first optical substrate and the optical film. In some embodiments, the first optical adhesive layer bonds the first optical substrate to the optical film. In some embodiments, the first optical adhesive layer may include a silanized amine. For example, in some embodiments, the silylated amine may include one or more of 3-aminophenyltrimethoxysilane (APTMS), 3-aminopropyltrimethoxysilane (APrTMS), 3-aminopropyltriethylsilane (APrTES), and 3-aminophenyltriethoxysilane (APTES). In some embodiments, the average thickness of the first optical bonding layer may be less than about 0.5 microns, or less than about 0.25 microns, or less than about 0.2 microns, or less than about 0.15 microns.

[0015] In some embodiments, the first optical substrate can be a plane parallel plate having relative first and second principal planar surfaces, such that the first principal surface of the first optical substrate is the first plane principal surface of the plane parallel plate. In some embodiments, the first optical substrate is curved and includes relative first and second curved principal surfaces, such that the first principal surface of the first optical substrate is the first curved principal surface of the curved first optical substrate. In some embodiments, the first optical substrate can be an optical lens having relative first and second principal surfaces, at least one of the first and second principal surfaces is curved, such that the first principal surface of the first optical substrate is one of the first and second principal surfaces of the optical lens.

[0016] In some embodiments, the optical film may include a plurality of polymer layers totaling greater than about 50 layers. In some embodiments, the optical film may include a reflective polarizer such that for substantially perpendicular incident light and for light of at least one wavelength, the reflective polarizer may reflect at least 60% of incident light having a first polarization state (e.g., light having a linear s-polarization state, also referred to as s-polarized light) and transmit at least 60% of incident light having an orthogonal second polarization state (e.g., p-polarized light). It should be noted that the polarization states discussed above are examples only and are not intended to be limiting. For example, the first polarization state may be p-polarized light and the second polarization state may be s-polarized light. As another example, the first polarization state may be a linear polarization type and the second polarization state may be a circular polarization state. In some embodiments, the plurality of polymer layers may form alternating first and second polymer layers, wherein the first polymer layer is substantially isotropic and the second polymer layer is substantially birefringent. In some embodiments, the birefringent second polymer layer may have in-plane refractive indices nx and ny along orthogonal directions, wherein the difference between nx and ny is greater than about 0.01. In some embodiments, the reflective polarizer can reflect at least 60% of incident light in the second polarization state for at least one wavelength in the infrared wavelength range.

[0017] In some embodiments, the optical film may include an optical reflector such that for substantially perpendicular incident light and for at least one wavelength in the visible wavelength range extending from about 400 nm to about 700 nm, the optical reflector reflects at least 60% of the incident light in each of the mutually orthogonal first and second polarization states. In some embodiments, for at least one wavelength in the infrared wavelength range extending from about 750 nm to about 1200 nm, the optical reflector transmits at least 60% of the incident light in each of the first and second polarization states. In some embodiments, the optical film may include an optical reflector such that for substantially perpendicular incident light and for at least one wavelength in the infrared wavelength range extending from about 750 nm to about 1200 nm, the optical reflector reflects at least 60% of the incident light in at least the first polarization state, and for at least one wavelength in the visible wavelength range extending from about 400 nm to about 700 nm, the optical reflector transmits at least 60% of the incident light in each of the first polarization state and the orthogonal second polarization state.

[0018] In some embodiments, the optical assembly may further include a second optical substrate having a first major surface and a second optical bonding layer. In some embodiments, the second optical bonding layer may be disposed between the first major surface of the second optical substrate and the optical film and in physical contact with the first major surface of the second optical substrate and the optical film, thereby bonding the second optical substrate to the optical film. In some embodiments, the second optical bonding layer may be a silylated amine. In some embodiments, the second optical bonding layer may have an average thickness of less than about 0.5 microns, or less than about 0.25 microns, or less than about 0.2 microns, or less than about 0.15 microns. In some embodiments, the first optical substrate may be a prism, and the first major surface may be a bevel of the prism. In some embodiments, the second optical substrate may be a second prism, and the first major surface of the second optical substrate may be a bevel of the second prism.

[0019] According to some aspects of the present specification, a polarizing beam splitter includes: a multilayer polymer reflective polarizer disposed between a first optical prism and a second optical prism; an optical bonding layer that physically contacts the reflective polarizer and bonds the reflective polarizer to each of the first optical prism and the second optical prism, wherein the first optical prism and the second optical prism cannot be separated from each other without damaging the reflective polarizer. In some embodiments, the optical bonding layer may have an average thickness of less than about 0.2 microns. In some embodiments, the polarizing beam splitter may have a reflected root mean square wavefront error of less than about 0.75 waves, or less than about 0.5 waves, or less than about 0.25 waves, or less than about 0.2 waves at a wavelength of 0.6328 microns. In some embodiments, the optical bonding layer may be a first optical bonding layer (bonding the first optical prism to the first side of the reflective polarizer) and a second optical bonding layer (bonding the second optical prism to the second side of the reflective polarizer).

[0020] According to some aspects of the present specification, a polarizing beam splitter includes: a multilayer polymer reflective polarizer disposed between a first optical prism and a second optical prism and including a first major surface and a second major surface relative to each other; a first optical bonding layer that physically contacts the first major surface of the reflective polarizer and bonds the first major surface of the reflective polarizer to the first optical prism; and a second optical bonding layer that physically contacts the second major surface of the reflective polarizer and bonds the second major surface of the reflective polarizer to the second optical prism; in some embodiments, the first optical prism and the second optical prism cannot be separated from each other without damaging the reflective polarizer. In some embodiments, for light having a wavelength of about 0.6328 microns incident on the polarizing beam splitter from each of the first major surface side and the second major surface side of the reflective polarizer, the polarizing beam splitter may have a reflected root mean square wavefront error of less than about 0.5. In some embodiments, the polarizing beam splitter may have a transmitted root mean square wavefront error of less than about 0.07 waves at a wavelength of 0.6328 microns.

[0021] According to some aspects of the present specification, an optical component is provided, the optical component comprising: a first optical substrate, the first optical substrate comprising a first major surface; an optical film (e.g., a reflective polarizer, an optical reflector, etc.) disposed on the first major surface of the first optical substrate so that for substantially vertically incident light and for each wavelength within a predetermined wavelength range extending at least 50 nanometers, the optical film reflects at least 60%, or at least 70%, or at least 80% of incident light of at least a first polarization state (e.g., light having a polarization state aligned with an x-axis or alternatively aligned with a y-axis); and a first optical bonding layer having an average thickness of less than about 0.5 microns and disposed between and in physical contact with the first major surface of the first optical substrate and the optical film, the first optical bonding layer bonding the first optical substrate to the optical film and comprising a silanized amine (e.g., APTMS, APrTMS, APrTES, APTES, etc.), and wherein the optical assembly has a reflected root mean square wavefront error of less than about 0.5 for light having a wavelength of 0.6328 microns incident on the optical film from each major side of the optical film.

[0022] Turning now to the accompanying drawings, Figures 1A-1C A diagram of a polarizing beam splitter according to embodiments described herein is provided. Figure 1A 1 is a perspective view of an optical assembly 100 (e.g., a polarizing beam splitter) comprising a first optical substrate 10 (e.g., a first optical prism) and a second optical substrate 50 (e.g., a second optical prism) separated by a multilayer optical film (MOF) reflective polarizer 20. In some embodiments, a first optical bonding layer 40 is disposed between a first major surface 11 of the first optical substrate 10 and the reflective polarizer 20. The first optical bonding layer 40 bonds the first optical substrate 10 to the reflective polarizer 20, and in some embodiments, comprises a silanized amine. The optical components are adhered to the nano-thick bonding layer using a silanized amine (e.g., a silane coupling agent), thereby producing an interface between the components with a relatively low wavefront error. In some embodiments, a second bonding layer 60 is disposed between the first major surface 51 of the second optical substrate 50 and the opposite side of the reflective polarizer 20.

[0023] Figure 1B Shows Figure 1A1 and 2. A side view of the optical assembly 100 of FIG. 1 provides additional details. The reflective polarizer 20 is characterized by a first major surface 24 and a second major surface 26, which are opposite sides of the reflective polarizer 20. In some embodiments, the first optical bonding layer 40 is disposed between and adheres the first major surface 11 of the optical substrate 10 and the first major surface 24 of the reflective polarizer 20. In some embodiments, the first optical bonding layer 40 has an average thickness t1 of less than about 0.5 microns, or less than about 0.4 microns, or less than about 0.3 microns. In some embodiments, the second optical bonding layer 60 is disposed between and adheres the first major surface 51 of the optical substrate 50 and the second major surface 26 of the reflective polarizer 20. In some embodiments, the second optical bonding layer 60 has an average thickness t2 of less than about 0.5 microns, or less than about 0.4 microns, or less than about 0.3 microns.

[0024] Figure 1C Shows Figure 1A and Figure 1B 1 is a side view of the optical component 100 when operating as a polarizing beam splitter. In the illustrated embodiment, incident light ray 200 representing unpolarized light enters one surface of the optical component 100 and thereby enters the second optical substrate 50 (i.e., the second optical prism 50). The light ray 200 passes through the second bonding layer 60 substantially unchanged and impinges on the surface of the reflective polarizer 20. In some embodiments, the reflective polarizer 20 allows light 200p of a first polarization state (e.g., p-polarized light) to be transmitted through the reflective polarizer 20, enter the first optical substrate 10 (i.e., the first optical prism 20), and causes light 200s of a second polarization state (e.g., s-polarized light) to be reflected (i.e., the light ray 200 is split into 200p and 200s). As shown in FIG. Figure 1C As shown, light ray 200p represents the transmitted wavefront and light ray 200s represents the reflected wavefront.

[0025] Figure 2A is a side view of an optical assembly 100a according to an embodiment described herein. In the illustrated embodiment 100a, the first optical substrate is a first plane parallel plate 10a including a first planar major surface 11a and an opposing second planar major surface 12a, and the second optical substrate is a second plane parallel plate 50a including a first planar major surface 51a and an opposing second planar major surface 52a. Figures 1A-1CLike the embodiment 100 of the present invention, the optical component 100a includes a multilayer polymer optical film (e.g., a reflective polarizer) 20 disposed between a first plane parallel plate 10a and a second plane parallel plate 50a. A first optical bonding layer 40 is disposed between the first plane parallel plate 10a and the optical film 20 (adhering the first plane major surface 11a to the first side of the optical film 20). A second optical bonding layer 60 is disposed between the first plane parallel plate 50a and the reflective polarizer 20 (adhering the first plane major surface 51a to the second side of the optical film 20). In some embodiments, the first optical bonding layer 40 has an average thickness t1 of less than about 0.5 microns, or less than about 0.4 microns, or less than about 0.3 microns. In some embodiments, the second optical bonding layer 60 has an average thickness t2 of less than about 0.5 microns, or less than about 0.4 microns, or less than about 0.3 microns. Utilizing the first plane parallel plate 10a and the second plane parallel plate 50a Figure 2A The illustrated embodiments may represent a polarizing window or lens for transmitting light of a certain polarization type (eg, p-polarized light or s-polarized light).

[0026] In some embodiments, the optical assembly may include only the first optical substrate 10a, and may not include the second optical substrate 50a and the second optical bonding layer 60. Figure 2B , an alternative embodiment of an optical assembly 100a' is shown. In other words, the concepts described herein are applicable to optical assemblies that include only a single substrate and a single optical bonding layer, and an optical film sandwiched between a first substrate and a second substrate is not required in all embodiments. Figure 2B All reference numerals repeated in Figure 2A Components with the same number in the drawings are identical to the components in the drawings and are not described further here.

[0027] Figure 3 is a side view of an optical component 100b having a curved surface according to an embodiment described herein. Figure 3 In the embodiments of the present invention, one or more of the first optical substrate 10b and the second optical substrate 50b can have one or more curved major surfaces. Figure 3The illustrated embodiment shows the two major surfaces 11b and 12b of the first optical substrate 10b and the two major surfaces 51b and 52b of the second optical substrate 50b as curved, but there may be some embodiments in which only a subset of these surfaces are curved. For example, in one embodiment, only the major surface 12b of the first optical substrate 10b can be curved, while the surfaces 11b, 51b and 52b (and the relative major surfaces of the optical film 20) are planar surfaces. Other exemplary configurations are also possible. For example, in some embodiments, the optical assembly 100b can include only the first optical substrate 10b and does not include the second optical substrate 50b or the second optical bonding layer 60.

[0028] In some embodiments, the multilayer polymeric optical film 20 of the preceding figures can be comprised of multiple layers of polymeric materials. Figure 4 An embodiment of an optical film 20 configured as a multilayer optical film (MOF) is shown. In some embodiments, the optical film 20 includes a plurality of alternating first polymer layers 21 and second polymer layers 22. In some embodiments, the number of combined alternating first polymer layers 11 and second polymer layers 22 may be between 50 and 700. In some embodiments, the first polymer layer 21 and the second polymer layer 22 may each have an average thickness of less than about 500 nm.

[0029] In some embodiments, the first polymer layer 21 can be substantially isotropic (i.e., exhibiting substantially the same refractive index when measured in different directions). In some embodiments, the second polymer layer 22 can be substantially birefringent (i.e., exhibiting two different refractive indices when measured in different orthogonal directions) and having in-plane refractive indices nx and ny along the orthogonal directions, wherein the difference between nx and ny is greater than about 0.01. Constructing the optical film 20 in this manner produces a MOF in which, when incident light 200 impinges on the film, at least 60%, or at least 70%, or at least 80%, or at least 90% of the incident light 200 having a first polarization state is reflected as reflected light 200s, and at least 60%, or at least 70%, or at least 80%, or at least 90% of the incident light 200 having a second polarization state is transmitted as transmitted light 200p (e.g., a reflective polarizer). As discussed elsewhere herein, although Figure 4 The examples are labeled to show light 200s being reflected and light 200p being transmitted, but the actual polarization states may be other than s-polarized light and p-polarized light. Any suitable different types of light polarizations may be used consistent with the description herein.

[0030] at last, Figure 5is a side view of an alternative optical assembly in the form of an optical lens assembly 100c. In the illustrated embodiment, a multilayer optical film 20 is adhered to an optical lens 10c having opposing first and second major surfaces 11c, 12c. In some embodiments, disposed between and adhering the optical film 20 and the optical lens 10c is an optical bonding layer 40. In some embodiments, at least one of the major surfaces 11c and 12c is curved. In some embodiments, both major surfaces 11c and 12c and the optical film 20 are curved. In some embodiments, the optical lens assembly 100c can allow light of a first polarization state (e.g., s-polarized light) to reflect from a surface of the optical film 20, and allow light of a second polarization state (e.g., p-polarized light) to be substantially transmitted through the optical film 20, through the optical lens assembly 100c. In some embodiments, and for some applications, the optical assembly 100c can also include a second optical substrate 50c and a second optical bonding layer 60 (see, e.g., Figure 2A and Figure 3 implementation plan).

[0031] Terms such as "about" will be understood by one of ordinary skill in the art in the context of use and description in this specification. If it is not clear to one of ordinary skill in the art in the context of use and description in this specification that "about" should be used to express the amount of feature size, quantity, and physical properties, then "about" will be understood to mean within 10% of the specified value. A quantity given as about a specified value may be exactly the specified value. For example, if it is not clear to one of ordinary skill in the art in the context of use and description in this specification, a quantity having a value of about 1 means that the quantity has a value between 0.9 and 1.1, and the value may be 1.

[0032] One of ordinary skill in the art will understand terms such as "substantially" in the context of use and description in this specification. If the use of "substantially equal" in the context of use and description in this specification is unclear to one of ordinary skill in the art, "substantially equal" will refer to approximately the situation of approximately as described above. If the use of "substantially parallel" in the context of use and description in this specification is unclear to one of ordinary skill in the art, "substantially parallel" will refer to within 30 degrees of parallel. In some embodiments, directions or surfaces described as being substantially parallel to each other may be within 20 degrees or within 10 degrees of parallel, or may be parallel or nominally parallel. If the use of "substantially aligned" in the context of use and description in this specification is unclear to one of ordinary skill in the art, "substantially aligned" will refer to alignment within 20% of the width of the object of alignment. In some embodiments, the objects described as being substantially aligned may be aligned within 10% or within 5% of the width of the object of alignment.

[0033] All references, patents, and patent applications cited above are hereby incorporated by reference in their entirety in a consistent manner. In the event of inconsistencies or conflicts between an incorporated reference portion and the present application, the information in the foregoing description shall prevail.

[0034] Unless otherwise indicated, the description of the elements in the drawings should be understood to apply equally to the corresponding elements in the other drawings. Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that the specific embodiments shown and described may be replaced with a variety of alternative and / or equivalent implementations without departing from the scope of the present disclosure. The present application is intended to cover any modification or variation of the specific embodiments discussed herein. Therefore, the present disclosure is intended to be limited only by the claims and their equivalents.

Claims

1. An optical component, comprising: a first optical substrate comprising a first major surface; a multilayer polymeric optical film disposed on the first major surface of the first optical substrate and comprising a plurality of polymeric layers numbering greater than 50 in total; and a first optical bonding layer having an average thickness of less than 0.5 micrometers and disposed between and in physical contact with the first major surface of the first optical substrate and the multilayer polymeric optical film, the first optical bonding layer bonding the first optical substrate to the multilayer polymeric optical film and comprising a silylated amine, Wherein, the optical component has a reflection root mean square wavefront error of less than 0.75 waves at a wavelength of 0.6328 microns.

2. An optical component according to claim 1, wherein the multilayer polymer optical film includes a reflective polarizer such that, for substantially vertically incident light and for at least one wavelength, the reflective polarizer reflects at least 60% of the incident light having a first polarization state and transmits at least 60% of the incident light having an orthogonal second polarization state.

3. The optical component of claim 1 , wherein the multilayer polymer optical film comprises an optical reflector such that for substantially vertically incident light and for at least one wavelength in the visible wavelength range extending from 400 nm to 700 nm, the optical reflector reflects at least 60% of the incident light in each of a first polarization state and a second polarization state that are mutually orthogonal.

4. The optical assembly of claim 3, wherein the optical reflector transmits at least 60% of the incident light in each of the first polarization state and the second polarization state for at least one wavelength in the infrared wavelength range extending from 750 nm to 1200 nm.

5. The optical component of claim 1 , wherein the multilayer polymeric optical film comprises an optical reflector such that for substantially normal incident light and for at least one wavelength in the infrared wavelength range extending from 750 nm to 1200 nm, the optical reflector reflects at least 60% of the incident light in at least a first polarization state, and for at least one wavelength in the visible wavelength range extending from 400 nm to 700 nm, the optical reflector transmits at least 60% of the incident light in each of the first polarization state and an orthogonal second polarization state.

6. The optical assembly of claim 5, such that for the at least one wavelength in the infrared wavelength range, the optical reflector reflects at least 60% of the incident light in the second polarization state.

7. The optical assembly of claim 1, wherein the first optical substrate is a prism, and the first major surface is a slope of the prism.

8. The optical assembly of claim 1, wherein the first optical substrate is a plane-parallel plate comprising opposing first and second planar major surfaces, and the first major surface is the first planar major surface of the plane-parallel plate.

9. An optical component according to claim 1, wherein the first optical substrate is an optical lens comprising a first major surface and a second major surface relative to each other, at least one of the first major surface and the second major surface is curved, and the first major surface is one of the first major surface and the second major surface of the optical lens.

10. The optical assembly of claim 1, further comprising: a second optical substrate comprising a first major surface; and A second optical bonding layer having an average thickness of less than 0.5 microns and disposed between and in physical contact with the first major surface of the second optical substrate and the multilayer polymeric optical film, the second optical bonding layer bonding the second optical substrate to the multilayer polymeric optical film and comprising a silylated amine.

11. A polarization beam splitter, comprising: a multilayer polymer reflective polarizer disposed between the first optical prism and the second optical prism; an optical bonding layer in physical contact with the reflective polarizer and bonding the reflective polarizer to each of the first optical prism and the second optical prism and having an average thickness of less than 0.2 microns and comprising a silylated amine, wherein the first optical prism and the second optical prism cannot be separated from each other without damaging the reflective polarizer, and wherein the polarizing beam splitter has a reflected root mean square wavefront error of less than 0.75 waves at a wavelength of 0.6328 microns.

12. A polarization beam splitter, comprising: a multilayer polymeric reflective polarizer disposed between the first optical prism and the second optical prism and comprising opposing first and second major surfaces; a first optical bonding layer, the first optical bonding layer and the reflective polarizer first major surface in physical contact with and bonding the first major surface of the reflective polarizer to the first optical prism, and the first optical bonding layer has an average thickness of less than 0.5 microns and comprises a silylated amine; and a second optical bonding layer, the second optical bonding layer being bonded to the reflective polarizer The polarizing beam splitter is configured to have a first optical prism and a second optical prism bonded to the second optical prism, wherein the first optical prism and the second optical prism are in physical contact with the second major surface and bonded to the second major surface of the reflective polarizer, and the second optical bonding layer has an average thickness of less than 0.5 microns and contains a silanized amine, wherein the first optical prism and the second optical prism cannot be separated from each other without damaging the reflective polarizer, and wherein for light with a wavelength of 0.6328 microns incident on the polarizing beam splitter from each of the first major surface side and the second major surface side of the reflective polarizer, the polarizing beam splitter has a reflected root mean square wavefront error of less than 0.5 waves.

13. The polarizing beam splitter of claim 12, having a transmission root mean square wavefront error of less than 0.07 waves at a wavelength of 0.6328 microns.

14. An optical component, comprising: a first optical substrate comprising a first major surface; an optical film disposed on the first major surface of the first optical substrate such that for substantially normal incident light and for each wavelength within a predetermined wavelength range extending at least 50 nanometers, the optical film reflects at least 60% of the incident light of at least a first polarization state; and a first optical bonding layer having an average thickness of less than 0.5 microns and disposed between and in physical contact with the first major surface of the first optical substrate and the optical film, the first optical bonding layer bonding the first optical substrate to the optical film and comprising a silylated amine, and wherein the optical assembly has a reflected root mean square wavefront error of less than 0.5 waves for light having a wavelength of 0.6328 microns incident on the optical film from each major side of the optical film.

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