Rapid prototyping of optical components, especially lenses, for producing custom optical surface shapes

Abstract

The invention relates to a method for producing at least one optical component, comprising the following steps: a) providing at least one cavity (2), wherein the at least one cavity (2) is delimited on a first side by a surface (3a) of a first film portion (3), wherein the shape of the first film portion (3) is adjustable; b) filling a material (4) into the at least one cavity (2) to form the at least one optical component (1), wherein the material (4) contacts the surface (3a) of the first film portion (3); c) adjusting the shape of the first film portion (3); d) curing the material (4) filled into the at least one cavity (2) such that the material (4) forms a first interface (e.g. a first optical surface) (1a) of the at least one optical component (1), which first interface (1a) comprises a shape delimited by the shape of the surface (3a) of the first film portion (3).

Description

[0001] Information related to divisional application This case is a divisional application. The parent application of this divisional application is the invention patent application filed on May 12, 2021, with application number 202180030402.4 and entitled "Rapid prototyping design of optical components, especially lenses, for producing customized optical surface shapes". Technical Field

[0002] This invention relates to a method for producing at least one optical component. Further, this invention relates to an optical device comprising at least one optical component produced using the method according to the invention. Further, this invention relates to an optical device having a customized optical surface, and an apparatus capable of performing the method according to the invention. Background Technology

[0003] In the manufacture of optical components, particularly lenses, challenges often arise from shaping individual parts efficiently and quickly while ensuring high optical performance. In particular, the use of traditional molds is relatively slow due to their long lead times, corresponding to the period from defining the part's shape to its completion. Furthermore, established processes such as grinding / 3D milling are relatively expensive and time-consuming. While 3D printing-based rapid prototyping is fast and cost-effective, it typically results in lower quality, especially when applied to lenses. Summary of the Invention

[0004] Based on the above, the problem to be solved by the present invention is to provide a method that enables the relatively rapid and cost-effective manufacture of optical components, such as lenses, while ensuring sufficient optical performance.

[0005] A method for producing at least one optical component includes the following steps: a1) provides at least one cavity (2). b1) Fill at least one cavity (2) with liquid material (4), c1) Adjust the shape of the first surface (4a) of the liquid material (4), d1) Solidify the liquid material (4) filled into at least one cavity (2) such that the liquid material (4) becomes a rigid material (40) and the first surface (4a) becomes a first interface (40a), wherein the shape of the first interface (40a) is defined by the shape of the first surface (4a), and either e1) At least one optical component is formed by a molding process, wherein a first interface (40a) provides at least one surface of the molding die and the shape of the optical surface of the optical component (1) is formed by the first interface (40a), or e2) The optical component includes a rigid material (40) and the first interface (40a) is the optical surface of the optical component (1).

[0006] In method step a1), at least one cavity is provided. Here and hereinafter, the cavity is a confined space demarcated by one or more solid structures. The solid structures can be elastically deformable, wherein the deformation of the solid structures is controllable. Therefore, the shape of the cavity can be adjustable. The cavity is arranged to carry liquid. The cavity can be arranged to completely demarcate the liquid on all sides. In particular, the cavity is liquid-tightly sealed. Alternatively, the cavity can be open to allow liquid flow through it. For example, the cavity includes a valve arranged to control the flow of liquid into and out of the cavity. The cavity can be arranged to move liquid within it in a predefined manner by pumping, convection, or tilting or rotating the cavity.

[0007] In step b1), a liquid material is filled into at least one cavity. Herein and hereinafter, the liquid material has a maximum viscosity of 100,000 mPa·s, preferably 1,000 mPa·s, and very preferably 100 mPa·s. The cavity is arranged to demarcate the liquid material on at least one side. According to a first alternative, the cavity may be completely filled with the liquid material. According to a second alternative, the cavity is partially filled with the liquid material, and additionally, the cavity is filled with a fluid (gas or liquid) wherein the fluid and liquid material are immiscible or have different densities. Thus, the liquid material and fluid are separated within the cavity.

[0008] According to one embodiment, the liquid material can be provided on a carrier, wherein in method step b1), the carrier is disposed within a cavity, or a solid structure defining the cavity includes the carrier. In particular, the liquid material is disposed on the surface of the carrier, wherein the surface is curved, includes nanostructures, includes protrusions and / or includes recesses. In particular, the carrier is a wafer, preferably comprising silicon, ceramic, or glass.

[0009] In particular, the cavity opens on one side, and on that other side, the liquid material is adjacent to a (gaseous or liquid) fluid material. In particular, the fluid material may be under ambient pressure.

[0010] A reservoir containing liquid material can be connected to a cavity. The cavity may include openings through which the liquid material flows in and out. In particular, the flow of liquid material within the cavity can be continuously controlled. Specifically, the liquid material is pumped to circulate the liquid material within the cavity or to flow the liquid material through the cavity, wherein the movement of the liquid material exceeds convective flow.

[0011] In method step b2), which is performed after method step b1), the cavity can be closed. Therefore, the opening through which the liquid material fills the cavity can be closed. In particular, the cavity is closed by distributing a flexible membrane on a first surface formed of the liquid material, wherein the flexible membrane is adjacent to the liquid material. For example, the cavity can be closed by solidifying a sub-region of the liquid material, thereby making the liquid material in said sub-region rigid.

[0012] In method step c1), the shape of a first surface of the liquid material is adjusted. The first surface may be adjacent to the fluid material. The shape of the first surface may be adjusted by controlling the contact angle of the liquid material relative to the structure defining the cavity. The shape of the first surface may be controlled by a continuous airflow that locally applies pressure to the first surface.

[0013] In particular, the volume of the cavity is adjusted in method step c1). For example, the cavity is connected to a reservoir comprising a liquid material. When the shape of the first surface is adjusted, the liquid material can flow between the reservoir and the cavity. The shape of the first surface can be adjusted by adjusting the relative pressure between the liquid material and the fluid material adjacent to the first surface. The shape of the first surface can be adjusted by adjusting the volume of the cavity. In particular, the first / second membrane portions may have non-uniform hardness. In particular, the first / second membrane portions are shaped in an aspherical manner when the shape of the first / second membrane portions is changed by means of different pressures on opposite sides of the membrane. The hardness of the first / second membrane portions may be anisotropic. In particular, the first / second membrane portions may have non-uniform thickness, which causes non-uniform hardness in the first / second membrane portions.

[0014] In method step d1), the liquid material is solidified, making the liquid material a rigid material and the first surface becomes the first interface, wherein the first interface has a shape substantially the same as the first surface, which is defined in method step c1). Here and hereinafter, the liquid material has a minimum viscosity of 100,000 mPa·s, preferably 1,000,000 mPa·s, and very preferably 10,000,000 mPa·s.

[0015] For example, liquid materials can be cured using UV radiation, where UV radiation is applied to sub-regions of the liquid material. Liquid materials can also be thermally cured, for example, by cooling the liquid material below its melting point or by heating the liquid material above its curing temperature.

[0016] In particular, the sub-regions were successively exposed to UV radiation.

[0017] In particular, UV radiation is applied in such a manner that liquid material is avoided from being included in the already cured rigid material during curing. For example, a central sub-region of the liquid material is exposed first, and the sub-regions surrounding the central sub-region are exposed sequentially. Advantageously, mechanical stress, cracks, and bubbles within the rigid material are reduced. For example, UV radiation is applied starting from the central sub-region, with subsequently exposed sub-regions arranged radially around the central sub-region. For example, UV radiation is applied in a point-like manner, where the diameter of the points increases successively. The point shape, position, and size can be controlled by means of adjustable optical components, such as adjustable lenses, adjustable mirrors, or adjustable prisms.

[0018] The liquid material can be cured in layers, wherein the liquid material layers subsequently solidify. In particular, the layers have a main extension direction that is perpendicular to the optical axis of the optical component. Specifically, the layer comprising the first surface and / or the second surface is the last layer to be cured.

[0019] In particular, the cavity includes a compensation region or a cavity adjacent to the compensation region. The compensation region is partially liquid-connected to the liquid material, which is solidified in method step d1). The compensation region has a variable volume, such that volume changes of the liquid material during hardening within the cavity are compensated for by changes in the volume of the compensation region. In particular, the compensation region may be designed to be open to the surrounding environment, such that volume changes of the compensation region are compensated for by atmospheric flow into the compensation region.

[0020] According to one embodiment, the shape of the first surface is altered during the solidification of the liquid material. For example, a first sub-region of the liquid material is solidified into a rigid material, while the liquid material in other sub-regions within the cavity remains unsolidified. Before another sub-region of the liquid material is solidified, the position of the rigid material within the cavity is manipulated to change the shape of the first surface. For example, after the first sub-region is exposed to UV radiation, a pin is pushed against the rigid material to change its position, thereby altering the shape of the first surface.

[0021] In particular, the temperature of the solid structure confining the cavity and / or the fluid material within the cavity are controlled. Specifically, the solidification of the liquid material can be locally initiated, delayed, or accelerated by controlling the temperature of the liquid material within the cavity. In particular, the temperature distribution within the liquid material is monitored during the solidification process in method step d1).

[0022] According to the first alternative in method step e1), the optical component is manufactured by a molding process, wherein the molding die comprises a rigid material. Specifically, the molding die defines the shape of the optical component, wherein a first interface defines the shape of the optical surface of the optical component. During the molding process, the first interface is adjacent to the manufactured optical component. The first interface provides mating portions for the optical surfaces of the optical component.

[0023] Rigid materials can be opaque to electromagnetic radiation in the visible light wavelength range. Advantageously, rigid materials can be optimized for bonding properties and mechanical properties, where the optical properties of the rigid material are negligible. Therefore, method step e1) implies fewer restrictions on the choice of rigid materials.

[0024] According to the second alternative in method step e2), the optical component comprises a rigid material. Specifically, the optical component is constructed of a rigid material. The first interface comprises the optical surface of the optical component. The optical component may be a refractive optical component, wherein the optical component is arranged to interact with light by providing an optical surface with a specific shape and a specific variation in refractive index. Specifically, the rigid material is substantially transparent to the light. Alternatively, the optical component may be a reflective optical component, wherein the optical surface is arranged to reflect electromagnetic radiation within a specific wavelength range. Specifically, metallization may be applied to the first interface to provide reflectivity to the optical surface. The metallization and shape of the first interface may define the optical properties of the optical surface. Specifically, the rigid material may be opaque to electromagnetic radiation that is desired to interact with the optical component.

[0025] According to one embodiment, in method step f2), which is performed after method step d1), rigid material is released from the cavity. In particular, the rigid material is ejected from the cavity by increasing the pressure inside the cavity and / or decreasing the pressure in a region adjacent to the cavity.

[0026] In particular, the solidification of the liquid material can be controlled, such that after method step d1), the liquid material layer is adjacent to the rigid material. Specifically, this liquid material layer can be arranged between the solid structure demarcating the cavity and the rigid material, which simplifies the release of the rigid material from the cavity. Furthermore, the liquid material is removed from the cavity after solidification in method step d1), preferably before the rigid material is released from the cavity.

[0027] The cavity may include an anti-adhesion layer or a sacrificial layer to facilitate the release of rigid material. If the cavity is delimited by a membrane portion, the membrane portion may be removed, dissolved, or ruptured when the rigid material is released from the cavity.

[0028] According to one embodiment, the rigid material is post-processed in method step f3) after method step d1). For example, the post-processing includes at least one of the following: - Exposing rigid materials to UV radiation; - Tempering rigid materials; - Coat rigid materials with scratch-resistant coatings, light-filtering coatings, anti-reflective coatings, or reflective coatings; - Exposing rigid materials to a vacuum.

[0029] In particular, post-processing may include processing the edge regions of the rigid material. As shown in the top view of the first interface, the edge region is the portion of the rigid material that defines the outer contour of the rigid material. Processing the edge region may include application processes, such as coating or blackening the edge region. Processing the edge region may include conversion processes, such as oxidation or plasma treatment of the edge region. Processing the edge region may include subtractive processes, in which portions of the rigid material are removed, for example by etching, grinding, punching, or cutting.

[0030] According to one embodiment, In method step a1), at least one cavity (2) is demarcated on a first side by the surface (3a) of the first membrane portion (3), wherein the shape of the first membrane portion (3) is adjustable; In method step b1), liquid material (4) is filled into at least one cavity (2) such that liquid material (4) contacts the surface (3a) of the first membrane portion (3). In method step c1), the shape of the first surface (4a) of the liquid material is adjusted by adjusting the shape of the first membrane portion (3).

[0031] According to one embodiment, a method for producing at least one optical component includes the following steps: a1) Provide at least one cavity, wherein the at least one cavity is demarcated on at least a first side by the surface of the first membrane portion, wherein the shape (and / or portion) of the first membrane portion is adjustable (e.g., by forming the first membrane into a desired shape). b1) Filling at least one cavity with liquid material to form at least one optical component, wherein the liquid material contacts a first surface of a first film portion; c1) Adjust the shape of the first membrane portion; d1) Solidify the liquid material filled into at least one cavity such that the solidified liquid material forms a first interface of at least one optical component, the first interface including a shape defined by the shape of a first surface of a first film portion.

[0032] According to a preferred embodiment, at least one optical component is a lens and the optical surface is the refractive surface of the lens. In particular, the first interface can form the first optical surface of at least one optical component. However, the actual first optical surface of at least one optical component can also be formed by a coating or layer disposed on the first interface. In particular, the first film portion can be retained on a rigid material. In this case, the first film portion preferably has the same refractive index as the cured rigid material.

[0033] Preferably, according to another embodiment, the rigid material is transparent when it solidifies. More preferably, the liquid material is initially liquid when it is filled into at least one cavity.

[0034] Furthermore, according to an embodiment of the method, in step a), at least one cavity is formed by an opening formed in a light-shielding plate, wherein a first membrane portion is connected to the light-shielding plate and covers the opening in order to delineate at least one cavity on the first side.

[0035] According to one embodiment, the opening of the light-shielding plate includes one of the following: a circular profile, a non-circular profile, an elliptical profile, and a polygonal profile.

[0036] Furthermore, according to one embodiment, the opening profile defines the profile of at least one optical component (e.g., a lens). In particular, the diameter of the opening can be less than 10 mm, preferably less than 5 mm.

[0037] Furthermore, according to one embodiment, the light-shielding plate forms the sidewall of at least one cavity.

[0038] According to another embodiment of the method, the light-shielding plate includes at least one channel (or multiple channels), through which at least one cavity in step b1) is filled with liquid material.

[0039] Furthermore, according to an embodiment of the method of this application, the light-shielding plate carries at least one optical component after the liquid material has been cured.

[0040] According to one embodiment, the method includes method step e1), wherein the adhesion of the optical component to the first interface is reduced by means of a coating applied to the first interface or film disposed between the first interface and the optical component, or by means of a nanostructure formed from the first interface. According to one embodiment, the method includes method step e2), wherein the reflection of light in the visible wavelength range at the first interface is reduced by means of a coating applied to the first interface or film, or by means of a nanostructure formed from the first interface.

[0041] Furthermore, in one embodiment, after the liquid material is cured in step d1), the first film portion is at least partially or completely removed from the light-shielding plate, and the first interface is coated and / or forms a first optical surface of at least one optical component. In an alternative embodiment, after the liquid material is cured, the first film portion remains on the cured material (i.e., on the first interface) and is coated and / or forms a first optical surface of at least one optical component.

[0042] This means that the first interface can form a final first optical interface, or that the final first optical surface can be formed by a layer (e.g., a coating) disposed on the first interface. In particular, the first optical surface can be formed by a portion of the first film or a layer (e.g., a coating) disposed thereon.

[0043] In particular, partial removal of the first membrane portion can mean that only one layer of the first membrane portion (e.g., a carrier layer, see below) is removed, while another layer of the first membrane portion (e.g., a layer) remains on the first interface.

[0044] Furthermore, particularly for providing the at least one channel (or multiple channels) for filling the liquid material into at least one cavity, the light-shielding plate includes first and second portions, wherein at least one channel is formed between the first and second portions. Specifically, the first and second portions of the light-shielding plate can each be formed as plates, which are in direct contact with or adjacent to each other to form corresponding channels. Specifically, the first and second portions have a main extension direction substantially parallel to the extension of the first film. Specifically, in order to separate at least one optical component in step d), the two portions (e.g., plates) can be separated from each other.

[0045] Furthermore, in a preferred embodiment of the method according to this application, the light-shielding plate is flexible. Because the light-shielding plate is flexible, it can be easily deformed to shape the first film portion into the desired form to adjust the surface of the first film portion and the first interface (particularly the first optical interface) of at least one optical component, which is manufactured using the method according to the invention.

[0046] According to another embodiment of the method, the opening of the light-shielding plate is surrounded by a transparent circumferential portion of the light-shielding plate, especially when the liquid material has been solidified (e.g., in step d), in order to define the lateral surface of at least one optical component (e.g., a lens).

[0047] According to one embodiment, the method includes method step e2), and in step a), an optical element is provided on one side of a light-shielding plate, facing away from the first surface. In particular, in step a), the optical element is provided on one side of the light-shielding plate, facing away from the first film portion, such that at least one cavity is disposed between the first film portion and the optical element.

[0048] In particular, in one embodiment, the optical element comprises a refractive index equal to that of the rigid material. Preferably, according to one embodiment, the optical element and the rigid material comprise the same material. Preferably, the optical element is bonded to the rigid material when the liquid material is solidified (e.g., in step d1).

[0049] Furthermore, according to one embodiment, the optical element includes a curved optical surface facing away from a liquid material filled into at least one cavity.

[0050] According to another embodiment of the method including method step e2), in method step a1), at least one cavity is demarcated on a second side opposite to the first side by the surface of the second film portion, wherein the shape (and / or position) of the second film portion is adjustable (e.g., by forming the second film portion into a desired shape). Therefore, the second film portion allows adjustment of the shape of the second interface (e.g., an optical surface) of at least one optical component.

[0051] Furthermore, according to the embodiment, method step b1) further includes filling at least one cavity with liquid material such that the liquid material also contacts the surface of the second membrane portion.

[0052] Furthermore, according to the embodiment, method step c1) further includes adjusting the shape of the second membrane portion.

[0053] Furthermore, according to the embodiment, step d1) further includes solidifying the liquid material filled into at least one cavity, such that the liquid material forms a second interface (e.g., an optical surface) of at least one optical component, the second interface including a shape defined by an adjusted shape of the surface of the second film portion.

[0054] According to one embodiment of the method including method step e2), step a1) further includes providing a carrier. The carrier may be part of a solid structure that confines the cavity.

[0055] In particular, method step d1) further includes removing the carrier from at least one optical component after the liquid material has been cured.

[0056] According to an alternative embodiment of the method, after the liquid material is cured in step d1), the carrier is formed into a mounting base for at least one optical component.

[0057] According to a preferred embodiment, the carrier is a printed circuit board. This is advantageous because the optical components are positioned directly relative to another component on the printed circuit board, which operably interacts with the optical components.

[0058] Preferably, according to another embodiment, the carrier includes at least one opening that can be aligned with a first surface, particularly a first film portion, and at least one cavity, wherein in step b1), liquid material preferably further fills the at least one opening for form-fitting attachment of at least one optical component to the carrier when the liquid material solidifies. In particular, step d1) further includes solidifying the liquid material filled into the at least one cavity and the at least one opening of the carrier to form-fit the at least one optical component to the carrier.

[0059] Advantageously, according to another embodiment, at least one opening of the carrier serves as an aperture for at least one optical component.

[0060] In an alternative embodiment, instead of an opening in the carrier, the carrier can be a transparent carrier. The transparent carrier may comprise glass or a polymer; preferably, the transparent carrier comprises the same material as the rigid material. The carrier includes a first side facing the liquid material filled into the cavity in method step b1), and a second side facing away from the first side of the carrier. In particular, the second side of the carrier faces the second membrane portion (see also below).

[0061] In particular, the transparent carrier is continuous, and the transparent carrier divides at least one cavity into a first region extending from a first side and a second region extending from a second side. In particular, the first region is disposed between the second membrane portion and the first side of the carrier, and the second region is disposed between the second membrane portion and the second side of the carrier.

[0062] Furthermore, in this respect, step b1) includes filling a first region of at least one cavity with liquid material such that the liquid material also contacts a first side of the carrier.

[0063] In particular, according to the embodiment, step d1) further includes curing the liquid material filled into a first region of at least one cavity, such that the rigid material is bonded to a first side of the carrier.

[0064] In particular, applying liquid material to both sides of the carrier and adjusting the shape of the first and second surfaces, especially adjusting the first and second film portions, and solidifying the liquid material on both sides of the carrier can be performed as independent process steps. That is, in steps b1), c1), and d1), the liquid material on the first side of the carrier is processed, while the liquid material on the second side of the carrier is processed in another step b2), c2), and d2). In other words, in the corresponding embodiment, the method includes other steps: b2) Filling the second region of at least one cavity with liquid material such that the liquid material contacts the second side of the carrier, particularly the surface of the second membrane portion; c2) Adjust the shape of the second surface of the liquid material in the second region; d2) The material filled into the second region of at least one cavity is solidified, such that the liquid material becomes a rigid material, and the second surface becomes a second interface, wherein the shape of the second interface is defined by the shape of the second surface, and such that the rigid material is bonded to the second side of the carrier. In particular, the second interface forms the optical surface of at least one optical component. The second interface may include a shape defined by the adjusted shape of the surface of the second film portion.

[0065] Furthermore, according to one embodiment, the first film portion includes an anti-reflective surface (AR surface). According to one embodiment, the AR surface is disposed on one side of the first film portion, facing away from the rigid material of at least one optical component.

[0066] According to an alternative embodiment, the first film portion includes a first surface structure, particularly a nanostructure, disposed on one side of the first film portion facing the rigid material of at least one optical component. Specifically, when the first film portion is removed from the solidified liquid material, the surface structure causes the first optical surface to become an anti-reflective first optical surface.

[0067] According to an alternative embodiment, the first film portion includes an anti-reflective layer (AR layer) disposed on one side of a carrier layer of the first film portion, the first film portion facing the liquid / rigid material of at least one optical component, wherein the AR layer comprises a refractive index between the refractive index of the rigid material and the refractive index of air, wherein after the liquid material is cured, the carrier layer of the first film portion is removed, and the AR layer remains on the cured material, particularly on at least one optical component.

[0068] According to a preferred embodiment, the AR layer includes nanostructures. Each nanostructure can be a moth-eye antireflective structure, i.e., an array comprising multiple nodules, each nodule having a size smaller than the wavelength of the incident light thereon. The nodules form a region of graded refractive index at the interface between the two media, significantly reducing the amount of light reflected from the interface.

[0069] In particular, in the same manner, the second membrane portion may include an AR layer, which can be formed in a manner similar to that described with respect to the first membrane portion.

[0070] Furthermore, according to one embodiment, the first film portion may include a scratch-resistant layer on one side, which faces away from the rigid material of at least one optical component. Here, in particular, the first film portion is held at a first interface and specifically forms a first optical surface.

[0071] Furthermore, according to an alternative embodiment, the first film portion may include a scratch-resistant layer disposed on one side of the carrier layer of the first film portion, the side facing the cured material. Here, in particular, after the liquid material is cured, the carrier layer of the first film portion is removed, and the scratch-resistant layer remains on the first interface and specifically forms the first optical surface.

[0072] The second film portion can be used in a similar manner to generate a scratch-resistant layer on the second optical surface.

[0073] In particular, in all embodiments, the liquid material is filled into at least one cavity (especially in the first and / or second region of at least one cavity) in a liquid state.

[0074] Furthermore, according to a preferred embodiment, step b) of the method further includes degassing the liquid material after filling the liquid material into at least one cavity (particularly after filling the liquid material into the first and / or second regions of the at least one cavity).

[0075] Liquid materials can be degassed, particularly after the liquid material has been filled into the cavity. Degassed liquid materials can be achieved by reducing their pressure, for example, by reducing the pressure of adjacent fluid materials. In particular, the cavity is arranged to apply ultrasound to the liquid material for degassed purposes. During the degassed liquid material, gas separated from the liquid material can be trapped within a dedicated area of ​​the cavity. In particular, gravity and / or centripetal force can be used to move the gas to the dedicated area. The gas separated from the liquid material can be continuously moved to the dedicated area by means of the liquid material within the cavity. Alternatively, the gas separated from the liquid material during degassed can be removed from the cavity. For example, the gas separated from the liquid can exit the cavity from the open side.

[0076] Regarding the shape adjustment of each film portion, which defines the shape of each interface / optical surface of at least one optical component, different techniques can be used according to the present invention. In particular, method steps c1) and / or c2) include at least one of them: - Deformable light shield (in particular, the deformable light shield enables the adjustment of astigmatism and prism of at least one optical component). - Apply pressure to the light-shielding plate at several points simultaneously; - Adjust the pressure of the liquid material and / or at least one ambient pressure outside the cavity; - Inhale or press the first membrane portion into the molding die and / or inhale or press the second membrane portion into the molding die; - Push the master plate toward the first film portion and / or push the master plate toward the second film portion [the master plate can be formed of a glass component, in particular a planar master plate (e.g. a planar glass component) is pushed toward the first film portion to tilt the first film portion so as to form at least one optical component within the prism]; - Change the distance between the first and second parts of the sunshade; - Change the distance between the first membrane section and the second membrane section - Rotate the liquid material such that the shape of the first and / or second (4b) surfaces is defined at least in part by the centrifugal force applied to the liquid material.

[0077] According to another embodiment, in method steps c1), c2), d1), and / or d2), the shape of the first and / or second surfaces is measured. In particular, the shape of the first film portion is measured (e.g., in a reflective mode or a transmissive mode) depending on the surface shape of the adjusted first film portion. Accordingly, the shape of the second film portion can also be measured (e.g., in a reflective mode or a transmissive mode).

[0078] The measuring unit may be arranged to measure the shape of a first and / or second surface. In particular, the shape of the first and / or second surface is adjusted via closed-loop control. The measuring unit may include a Sack Hartmann sensor. Specifically, the Sack Hartmann sensor may include adjustable optical components, such as adjustable lenses or adjustable prisms, for illumination or imaging.

[0079] In particular, the measuring unit is arranged to measure the relative deviation of the shape of the first / second surface relative to the shape of the reference lens. The measuring unit may include a single-point system arranged to measure the single-point deflection of the first / second surface. In particular, the measuring unit may be arranged to generate a point cloud of the deflection of the first / second surface. For example, the measuring unit includes a projector arranged to project a grid pattern onto the first / second surface, wherein the measuring unit is arranged to determine the shape of the first / second surface by imaging the projected grid projection.

[0080] In another preferred embodiment of the method according to the invention, the shapes of the first surface (4a) and / or the second surface (4b) are repeatedly adjusted. In particular, the shapes of the first and second surfaces are measured and adjusted simultaneously or alternately. Further, according to one embodiment, the shapes of the first and second film portions are repeatedly adjusted, wherein the shapes of the first and second film portions are measured and adjusted simultaneously or alternately.

[0081] In particular, according to one embodiment, it is possible to measure the first and / or second interfaces (e.g., optical surfaces) of at least one optical component before curing the liquid material.

[0082] Furthermore, according to a preferred embodiment of the method of the present invention, the liquid material is irradiated with ultraviolet light (e.g., in step d1 or d2) to solidify the liquid material.

[0083] In particular, in one embodiment, the light-shielding plate can be arranged to block a portion of ultraviolet light, thereby defining the outline of at least one optical component. Specifically, the light-shielding plate can define a non-circular outline of at least one optical component. Furthermore, multiple optical components can be manufactured simultaneously within the cavity, wherein the light-shielding plate can be arranged to shield the area between adjacent optical components from UV radiation. This structure of the light-shielding plate safeguards the separation of multiple optical components because the liquid material between adjacent optical components remains liquid. Therefore, after curing, the optical components (e.g., lenses) are not interconnected by a rigid material. For example, excess liquid material can be rinsed away to separate the optical components.

[0084] Furthermore, according to one embodiment, ultraviolet light is emitted such that it uniformly irradiates (in particular, targets) the liquid material filled into at least one cavity.

[0085] In particular, in one embodiment, to prevent uneven curing caused by the curvature of the first surface, especially the first film portion, a transition liquid is disposed on top of the first film portion. This transition liquid comprises a refractive index equal to the refractive index of the liquid material, particularly the refractive index of the rigid material of at least one optical component. Thus, the refraction of ultraviolet light is avoided when propagating from the transition liquid to the liquid material.

[0086] According to an embodiment of the method, at least one sub-region of the liquid material of an optical component is successively solidified.

[0087] According to one embodiment, the liquid material can be successively solidified from opposite sides of at least one cavity.

[0088] In particular, according to one embodiment, the liquid material includes first and second sub-regions, wherein the first sub-region first solidifies to become a fixed point, and wherein the second sub-region subsequently solidifies, wherein the second sub-region is adjacent to the first sub-region.

[0089] For example, in one embodiment, at least one optical component is a lens array comprising a plurality of lenses, wherein the edges of the lens array (forming a first sub-region) are first solidified, and the lenses of the lens array (forming a second sub-region) are subsequently solidified.

[0090] Furthermore, according to one embodiment, ultraviolet light is emitted through an aperture, wherein the aperture diameter changes during the curing of a liquid material of at least one optical component.

[0091] Furthermore, according to one embodiment, during the curing process, the shape of the first surface, particularly the first film portion, and / or the second surface, particularly the second film portion, can be changed, wherein different sub-regions of the liquid material of at least one optical component are successively cured.

[0092] According to another embodiment, a liquid material is solidified by means of a light beam (particularly a laser beam), the beam having a diameter smaller than that of at least one optical component, wherein the light beam scans a first surface to solidify the liquid material. Similarly, in one embodiment, such a light beam is capable of scanning a second surface.

[0093] Furthermore, according to one embodiment, the ultraviolet light used to cure the liquid material of at least one optical component is patterned ultraviolet light. In particular, in one embodiment, the ultraviolet light is patterned by a liquid crystal display (LCD) projector or a digital light processing (DLP) projector.

[0094] According to an alternative embodiment, in order to solidify the liquid material (e.g., in step d1 or d2), the liquid material of at least one optical component is heated.

[0095] Furthermore, according to an embodiment of the method, the light-shielding plate is removed after the liquid material of at least one optical component has been cured.

[0096] In particular, in one embodiment, the first and / or second membrane portions are removed from the rigid material. Specifically, the first and / or second membrane portions can be removed by peeling.

[0097] Furthermore, in one embodiment, after curing the liquid material of at least one optical component, the first film portion is at least partially or completely removed, and the first interface is coated and / or forms a first optical surface of at least one optical component. Alternatively, after curing the liquid material, the first film portion remains on a rigid material and is coated and / or forms a first optical surface of at least one optical component.

[0098] According to another embodiment, after curing the liquid material of at least one optical component, the second film portion is at least partially or completely removed, and the second interface is coated and / or forms a second optical surface of at least one optical component. Alternatively, after curing the liquid material of at least one optical component, the second film portion remains on the cured liquid material and is coated and / or forms a second optical surface of at least one optical component.

[0099] In particular, in this context, partially removing the corresponding membrane portion can mean that only one layer of the corresponding membrane (e.g., the carrier layer, see below) is removed, while another layer (e.g., the layer) of the corresponding membrane portion remains on the first interface.

[0100] Furthermore, in one embodiment, the AR layer, such as a coating (see also below), is disposed between the carrier layer of the first film portion and the rigid material, and is able to remain on the first interface. Similarly, the AR layer, such as a coating (see also below), is disposed between the carrier layer of the second film portion and the rigid material, and is able to remain on the second interface of at least one optical component.

[0101] According to another embodiment, the method is used to produce multiple optical components.

[0102] Therefore, in method step a1), a plurality of cavities are provided. Each of the plurality of cavities may be demarcated on at least one side by means of the surface of a first membrane portion (e.g., flexible), wherein the shape of the corresponding first membrane portion is adjustable (e.g., by shaping the corresponding first membrane portion into a desired shape).

[0103] In method step b1), each of the plurality of cavities is filled with a liquid material, wherein for each of the plurality of cavities, the liquid material forms a first surface. In particular, an optical component is formed in each cavity. For example, the liquid material contacts the surface of the corresponding first film portion.

[0104] In method step c1), the shape of the first surface is adjusted, in particular, by adjusting the shape of the first film portion.

[0105] In method step d1), the liquid material is solidified, such that the liquid material becomes a rigid material and the first surface becomes a first interface (e.g., an optical surface), wherein the shape of the first interface is defined by the adjusted shape of the first surface.

[0106] In particular, all embodiments described herein can include the formation of multiple optical components, rather than at least one. The light-shielding plate includes a corresponding number of openings and a first film portion, and in particular, a second film portion.

[0107] In fact, according to an embodiment of the method, each of the plurality of cavities is formed by an opening formed in a light-shielding plate, wherein a corresponding first film portion is connected to the light-shielding plate and covers the corresponding opening, so as to delineate the corresponding cavity on at least one side.

[0108] Suppose there is more than one cavity, and each first membrane portion can be formed by a separate (e.g., flexible) first membrane. However, the first membrane portions may alternatively originate from components of a single (e.g., flexible) first membrane. The same applies to the second membrane portions, i.e., the second membrane portions can each be formed by a separate (e.g., flexible) second membrane, or alternatively originate from components of a single (e.g., flexible) second membrane.

[0109] According to one embodiment, regarding step a1), the corresponding cavity is demarcated by the second membrane portion on a second side opposite to the first side, wherein the shape (and / or position) of the corresponding second membrane portion can be adjusted (e.g., by forming the corresponding second membrane portion into the desired shape).

[0110] In particular, in one embodiment, step b1) further includes filling the corresponding cavity with liquid material such that the liquid material also contacts the surface of the corresponding second membrane portion; Furthermore, in one embodiment, step c1) further includes adjusting the shape of the corresponding second membrane portion.

[0111] Furthermore, according to one embodiment, step d1) further includes solidifying the liquid material filled into the corresponding cavity, such that the liquid material forms a second interface (e.g., an optical surface), the corresponding second interface including a shape defined by the adjusted shape of the surface of the corresponding second film portion.

[0112] Furthermore, in the case of several cavities and / or several first film portions and especially second film portions, after the liquid material is solidified, the corresponding film portions can be removed or can remain on the corresponding interfaces, such that the corresponding optical surfaces are formed either by the interface (or by the layers / coatings disposed thereon) or by the corresponding film portions (or by the layers / coatings disposed thereon) of the first / second film portions.

[0113] According to a preferred embodiment, the optical components are connected to each other to form an optical component array, wherein each optical component is a lens (i.e., the optical component array is a lens array).

[0114] In particular, after the liquid material is solidified, excess liquid material between adjacent optical components is removed.

[0115] According to another embodiment, in method step f1), individual optical components (particularly lenses) are cut out of the array, particularly by means of at least one of: grinding, laser cutting, stamping, cutting, or punching. Method step f1) is performed after method step d1). In particular, method step f1) includes method step f2) and / or method step f3).

[0116] According to one embodiment, the method includes method step e2) and additional method steps b2), c2), and d2), wherein additional interfaces are fabricated, which form additional optical surfaces of the optical component. In particular, method steps b2), c2), and d2) can be repeated multiple times to form a plurality of additional interfaces, wherein each additional interface can have a separate shape. Rigid materials formed in a continuous manner are adjacent to each other and have different refractive indices. Thus, the additional interfaces respectively form refractive surfaces on the optical component.

[0117] In method step b2), additional liquid material is filled into at least one cavity, wherein the additional liquid material is adjacent to the interface formed in the aforementioned method steps d1) or d2). In the case of performing multiple iterations of method steps b2), c2), and d2), the additional liquid material is adjacent to the interface formed in the aforementioned iterations, respectively.

[0118] In method step c2), the shape of the additional surface is adjusted, wherein the additional surface (4c) is arranged on one side of the additional liquid material, which is opposite to the interface (40a) made in the aforementioned method steps d1) or d2).

[0119] In method step d2), the additional liquid material is solidified, such that the additional liquid material becomes an additional rigid material and the additional surface (4c) becomes an additional interface (40c), wherein the shape of the additional interface (40c) is defined by the shape of the additional surface (4c). Method steps b2), c2) and d2) are performed after method step d1).

[0120] Rigid materials and additional rigid materials can form refractive optical components, which can be achromatic lenses, highly achromatic lenses, or super achromatic lenses. In particular, the rigid materials and additional rigid materials have different Abbe numbers and different refractive indices. Furthermore, the rigid materials and additional rigid materials are firmly bonded at an interface or additional interface in a form-fitting manner. Therefore, the optical component comprises the rigid material and additional rigid materials, which are formed integrally.

[0121] Advantageously, the present invention can be used to leave blank spaces for eyeglasses, augmented and virtual reality helmets, endoscopes, camera lenses, and any spherical and aspherical lenses, prisms, and any other optical components.

[0122] Another aspect of the present invention relates to an optical device comprising at least one optical component (or multiple optical components) produced using the method according to the present invention.

[0123] Another aspect of the present invention relates to an optical device, comprising: - Rigid materials, - Components that are at least partially embedded in a rigid material The optical device includes at least one optical surface configured to influence the interaction of light with the component in a predefined manner, wherein the at least one optical surface is formed of one of the following: a rigid material, a layer disposed on the rigid material (e.g., anti-reflective and / or scratch-resistant), or a film portion disposed on the rigid material.

[0124] Moreover, the membrane portion can include this layer or any other coating.

[0125] According to a preferred embodiment of this optical device, the component is fully embedded in a rigid material such that the latter covers the component on all sides.

[0126] According to another embodiment, the embedded component is one of the following: electronic components; optical components, diffraction gratings, apertures, filters, optoelectronic components, decorative elements, sensors, and light sources.

[0127] According to another embodiment of the optical device, at least one optical surface is formed of a liquid rigid material.

[0128] According to another aspect of the invention, an apparatus for producing at least one optical component is disclosed, the apparatus comprising: - At least one cavity (2) for containing liquid curable material (4). - An actuator unit for defining the shape of the first surface (4a) of the liquid solidifiable material (4) within the cavity (2), and - Curing unit (102), used to cure liquid material (4) when liquid material is in at least one cavity (2).

[0129] According to one embodiment of the apparatus for producing at least one optical component, including - Sunshade, including openings, - A first film portion, connected to a light-shielding plate and covering an opening, to demarcate the at least one cavity on a first side, wherein the first film portion includes a surface that defines the shape of a first interface (e.g., an optical surface) for manufacturing at least one optical component when liquid material is filled into the at least one cavity and contacts the surface of the first film portion. - An actuator unit configured to adjust the shape of a first film portion to adjust the interface shape of at least one optical component, and - A curing unit for curing liquid material when it is filled into at least one cavity.

[0130] According to an embodiment of the device, the curing unit can be an ultraviolet light source configured to emit ultraviolet light, or a heater configured to heat the liquid material in the chamber, or a cooling device configured to cool the liquid material.

[0131] According to another embodiment of the device, the device may include a mounting base configured to carry at least one cavity, which is limited on at least one side by a first membrane portion.

[0132] According to another embodiment of the device, the device includes a filling unit configured to fill at least one cavity with the liquid material. Attached Figure Description

[0133] Further features and advantages of the present invention, as well as embodiments thereof, will now be described with reference to the accompanying drawings, wherein... Figure 1 A schematic diagram of an embodiment of the method according to the present invention is shown for producing optical components with customized optical surfaces; Figure 2 An embodiment is shown that adjusts the film portion to shape an optical surface; Figure 3 Another embodiment of the method according to the invention is shown, in which a light-shielding plate with channels is used to apply liquid material in order to form an optical component; Figure 4 Another embodiment of the method according to the invention is shown, using a carrier for demarcating the cavity, which is used to form optical components in a two-step curing process; Figure 5 Another embodiment of the method according to the invention is shown, using an optical element to which a rigid material is bonded during curing; Figure 6Another embodiment of the method according to the invention is shown, using an optical element to which a rigid material is bonded during curing; Figure 7 Another embodiment of the method according to the invention is shown, wherein the optical surface of the optical component is shaped by adjusting the pressure P1 of the liquid material relative to ambient pressures P2 and P3; Figure 8 Another embodiment of the method according to the invention is shown, wherein the optical surfaces of the optical components are shaped by means of molding liquids L1 and L2 affected by gravity; Figure 9 Another embodiment of the method according to the invention is shown, using a carrier to which a rigid material is bonded during curing, wherein the carrier forms the aperture of the optical component; Figure 10 Another embodiment of the method according to the invention is shown for producing optical components constituting a prism; Figure 11-12 A top view of an apparatus for performing the method according to the invention is shown. Figure 11 ) and cross-sectional view; Figure 13 An exemplary embodiment of a method for producing at least one optical component is illustrated in schematic cross-sectional view, wherein the shape of a first surface is defined by a piston; Figure 14a and 14b An exemplary embodiment of a method for producing at least one optical component is illustrated in schematic cross-sectional view, wherein an additional interface is fabricated; Figure 15 An exemplary embodiment of a method for producing at least one optical component is illustrated in schematic cross-sectional view, wherein the shape of the first and / or second surface is measured by a measuring unit; Figure 16 An exemplary embodiment of a method for producing at least one optical component is illustrated in a schematic cross-sectional view, wherein the shape of the second surface is defined by an actuation unit 101. Detailed Implementation

[0134] Figure 1The general concept of the method according to the invention is shown. The method uses a cavity 2 defined on one side by a first film portion 3. The first film portion 3 includes a surface 3a, which will be contacted by a liquid material 4 filled into the cavity 2. While the material is in a liquid state, the film 3 is adjusted to form, for example, a convex lens surface. The liquid material 4 filled into the cavity 2 can then be cured by heating 8 or ultraviolet light 8, depending on the liquid material 4. The optical component 1 then includes an interface 1a, in this case, in the form of an optical surface 1a, which includes a shape corresponding to the shape of the surface 3a of the first film portion 3. Generally, the actual optical surface can be formed by the interface 1a, but it can also be formed by a layer (e.g., a coating) disposed on the interface 1a. In particular, the first film portion 3 can be held on the cured material 4 / interface 1a and subsequently form the actual optical surface. Moreover, here, the first film portion 3 can be further processed to form an optical surface using the first film portion 3 as a base.

[0135] In particular, generally, the curable liquid material can be a UV-curable polymer, which is preferably transparent to visible light.

[0136] In particular, the cavity 2 can be formed by an opening 5a formed in a light-shielding plate 5, which forms the sidewall 5b of the cavity 2 and thereby defines the side profile of the optical component 1 to be manufactured. The opening 5a is covered by a first membrane portion 3, which is preferably flexible, in order to delineate the cavity 2 and retain the liquid / rigid material 4 within the cavity 2.

[0137] In order to adjust the shape of surface 3a and the consequent optical surface 1a, force 10 is applied to flexible light shield 5, wherein the force extends in particular along an optical axis that extends perpendicular to the light shield 5. Figure 2 An example is shown where an optical surface 1a becomes convex by applying a force 10 to either side of the opening 5a in the light-shielding plate 5. The force can be different, for example, to form the optical component as a prism.

[0138] Figure 3 It shows Figure 1 and 2 The embodiment shown is modified in that, here, the light shield 5 includes at least one channel 7 for filling the cavity 2 of the light shield with liquid material.

[0139] In particular, the light-shielding plate 5 can include first and second portions 51, 52, which are stacked together and form a common structure. Figure 3 At least one channel 7 in the stacked structure of portions 51 and 52 shown. However, channel 7 can also be formed in other ways.

[0140] Furthermore, cavity 2 can be formed through opening 5a of light shield 5, which is demarcated on two opposite sides by flexible first membrane portion 3 and flexible second membrane portion 6.

[0141] Using this light-shielding plate 5 structure, an optical component 1 with two opposing optical surfaces 1a, 1b is generated, which can be shaped according to the surface 3a, 6a of the corresponding membrane portions 3, 6, wherein the corresponding membrane portions 3, 6 are contacted by the liquid material 4 when the liquid material 4 is filled into the cavity 2 through at least one channel 7.

[0142] Once surfaces 3a and 6a are shaped as needed, the liquid material in cavity 2 can be solidified to form optical component 1 (here, for example, a biconvex lens 1).

[0143] exist Figures 1 to 3 The diagram shows only a single cavity 2. However, the method also includes embodiments using multiple such cavities 2, arranged side-by-side, such that multiple optical components 1 are formed side-by-side. Ultimately, the optical components 1 can be separated from each other to form a single optical device 1. Alternatively, the optical components 1 can also remain interconnected to form an optical device in the form of an array of interconnected optical devices 1, such as a lens array.

[0144] The production of such a lens array, consisting of multiple optical components 1 in a two-step process, is exemplified by... Figure 4 As shown in the image.

[0145] Here, the light-shielding plate 5 includes a plurality of openings 5a, each opening 5a framing a flexible first membrane portion 3. The first membrane portion 3 may extend continuously between the light-shielding plate 5 and the cavity 2. Alternatively, each opening 5a may be sealed by means of separate first membrane portions 3.

[0146] In particular, the interconnected optical components 1 can be cured in two steps. In the first step, the cavity 2 is demarcated by a light-shielding plate 5, a film portion 3 on one side, and a carrier 9 arranged opposite the light-shielding plate 5 and the film portion 3, such as... Figure 4 The upper half is shown. After the surface 3a has been shaped as needed, the interconnected cavities 2 are filled with liquid material 4. Then, after obtaining the first half of the final array of optical components 1 in the first curing step, the cured half is flipped and the carrier 9 is removed. During the second step, the cured half now demarcates the cavity 2 instead of the carrier. The cavity 2 is demarcated by the cured half of the array of optical components 1 and the light-shielding plate 5 with the film portion 3, and the cavity 2 is then filled with liquid material 4, which is then bonded to the already cured half during curing. This results in the array of optical components 1, in the form of a biconvex lens. However, arrays of other optical components 1 can also be formed in this manner.

[0147] Figure 5Another variation of the method according to the invention is shown. Here, for example, a blank optical element 11 is used, which is demarcated as a cavity (or multiple cavities) 2 on one side opposite the first film portion 3. During curing, the optical element 11 is bonded to the rigid material 4. In particular, the rigid material 4 and the optical element 11 may have the same refractive index. Further, the optical element 11 may have a concave or convex surface 11a facing away from the rigid material 4.

[0148] In particular, after the liquid material 4 is solidified, the thickness along the z-direction of the rigid material 4 is less than the thickness along the z-direction of the optical element. For example, the optical element is selected such that the deviation of the shape of the first surface 4a from the surface of the optical element 11 facing the rigid material 40 is minimized. In particular, the rigid material 40 has a non-uniform thickness, wherein the thickness is measured along the z-direction. For example, the minimum thickness of the rigid material along the z-direction is at most 0.5 mm, preferably at most 0.1 mm, and very preferably at most 0.05 mm.

[0149] according to Figure 6 In another embodiment shown, the light-shielding plate 5 can be made of an opaque material. Therefore, the light-shielding plate 5 defines the outline of a portion of the liquid material, which is achieved by means of... Figure 6 Curing is performed using ultraviolet light 8 or heating 8 as shown.

[0150] Figure 7 Another possibility for shaping the surfaces 3a and 6a of the film portions 3 and 6 is shown in order to shape the final optical surfaces 1a and 1b of the optical component 1 produced using this method. In particular, Figure 7 The illustrated embodiment uses Figure 3 The structure shown has multiple interconnected cavities 2, which are arranged laterally side by side.

[0151] To adjust the shapes of the first and second membrane portions 3 and 6, the pressure P1 of the liquid material 4 filled into the cavity 2 is adjusted relative to the ambient pressures P1 and P2 on either side of the light-shielding plate 5, resulting in convex and concave optical components / lenses 1. However, other surface shapes 1a and 1b can be easily generated depending on the pressures P1, P2, and P3.

[0152] further, Figure 8 One embodiment is shown in which the shape of the first membrane portion 3 is adjusted by two molding liquids L1 and L2. The density ratio of the molding liquids L1 and L2 relative to each other and relative to the liquid material 4, as well as the height of the liquids L1 and L2, are selected such that the desired shape of the first membrane portion is as follows: Figure 8 As shown.

[0153] Figure 9Another embodiment of the method according to the invention is shown. Here, a carrier 9 is arranged within the cavity 2. In particular, the carrier 9 can be a printed circuit board (PCB). The carrier 9 includes an opening 9a aligned with two opposing film portions 3, 6, namely the first film portion 3 and the second film portion 6, such that the opening 9a ultimately forms the aperture of the optical component 1 to be manufactured.

[0154] In particular, after the shapes of membrane portions 3 and 6 have been adjusted as needed, liquid material 4 is arranged within opening 9a and above and below carrier 9. Figure 9 (Upper half). In order to solidify the liquid material 4, the liquid material 4 is preferably exposed to ultraviolet light 8 from both sides to avoid the liquid material 4 being blocked by the carrier 9.

[0155] When liquid material 4 is solidified ( Figure 9 After the middle section, the light-shielding plate 5 and the uncured liquid material 4 are removed. In particular, the film portions 3 and 6 are removed. Since the opening 9a is filled with material 4, the optical component 1 can be connected to the carrier (see reference) in a form-fitting manner. Figure 9 (Lower half). In particular, the carrier 9 may include light-emitting and / or light-detecting elements. The light-emitting and / or light-detecting elements may be embedded through the cured material 4. In particular, the optical component 1 may be part of a gas sensor.

[0156] Furthermore, instead of providing an opening 9a, the carrier can also be continuous but transparent. The carrier 9 then divides the cavity 2 into first and second regions 2a and 2b. Here, the liquid material can be processed independently on either side of the carrier 2. For example, after the shape of the first membrane portion 3 has been adjusted, the liquid material 4 can be filled into the first region 2a of the cavity 2 between the first membrane portion 3 and the first side 91 of the carrier 9, and can then be solidified to form the first optical surface 1a of the optical component 1. In another step, after the shape of the second membrane portion 6 has been adjusted, the liquid material 4 can be filled into the second region 2b of the cavity 2 between the second membrane portion 6 and the second side 92 of the carrier 9, and can then be solidified to form the second optical surface 1b of the optical component 1.

[0157] Using the method according to the invention, it is also possible to produce optical components in the form of prisms or including prisms, such as... Figure 10 As shown.

[0158] Here, the first membrane portion 3 can also be made of a rigid material. The tilt of the first membrane portion 3 can be adjusted by applying force to the light-shielding plate 5, and in particular by adjusting the pressure of the liquid material relative to the environment. The liquid material can be cured by irradiating it with ultraviolet light 8 that passes through the first membrane portion 3. Within the framework of the present invention, the tilt position of the first membrane portion 3 is also considered to be in relation to the shape of the first membrane portion 3.

[0159] In particular, the method according to the invention can be used by... Figure 11 and 12 This is implemented using the example of device 100. Such device 100 can be easily adapted to the individual embodiments described above.

[0160] In particular, the device 100 includes a light-shielding plate 5 (see also above) which includes at least one opening 5a with a first membrane portion 3 covering the opening 5a. The light-shielding plate 5 and the first membrane portion 3 define the cavity 2 on at least one side. A filling unit is arranged to fill the cavity 2 with liquid material 4.

[0161] In particular, the device includes an actuator unit 101 comprising a plurality of actuators 103 circumferentially arranged around the first membrane portion 3. Specifically, the actuators 103 are configured to apply force to the light-shielding plate 5 along the z-axis (e.g., the optical axis). This adjusts the position of the light-shielding plate 5 along the z-axis. For example, the device 100 includes at least four actuators 103, preferably at least eight. Preferably, the actuators 103 are equidistantly spaced along the circumference of the first membrane portion 3 (or along the opening 5a). By adjusting the position of the light-shielding plate 5 along the z-axis, the shape of the first membrane portion is adjusted, which in turn determines the final shape of the optical surface 1a of the optical component 1, produced by the device 100 due to the fact that the liquid material 4 will contact the surface 3a of the first membrane portion 3 and thereby shape the surface 3a of the first membrane portion 3.

[0162] Furthermore, the device preferably includes a curing unit 102, such as ultraviolet light, for generating ultraviolet light 8 (or alternatively, a heater for heating the liquid material 4). After the shape of the first film portion 3 has been adjusted by the actuator 103, the curing unit 102 is arranged to cure the liquid material 4, for example as... Figure 12 As shown.

[0163] The method according to the present invention enables cost-effective and rapid production of custom optical surfaces with high optical performance.

[0164] Figure 13 An exemplary embodiment of a method for producing at least one optical component is illustrated in schematic cross-sectional view, wherein the shape of the first surface 4a is defined by a piston 71. The piston 71 and the first membrane portion 3 demarcate the cavity 2, which is disposed on two opposite sides in method step a1). A light-shielding plate 5 laterally demarcates the cavity 2.

[0165] In step b1), liquid material 4 can be filled into cavity 2 through injection port 72. Injection port 72 is integrally formed inside piston.

[0166] The first surface 4a of the liquid material 4 is adjacent to the first membrane portion. In method step c1), the shape of the first surface 4a of the liquid material 4 is adjusted by changing the pressure within the cavity 2. The pressure can be changed by moving the piston toward or away from the first membrane portion 3 and / or by filling the cavity with more or less liquid material 4 through the injection port 72.

[0167] In particular, the shape of the second surface 4b is defined by the shape of the piston 71. The piston 71 may include a rigid lens having a mating portion with the desired shape for forming the second surface 4b. In particular, the rigid lens of the piston 71 may be manufactured according to method steps a1), b1), c1), d1), and e1).

[0168] In method step d1), the liquid material 4 is solidified, making the liquid material 4 a rigid material 40 and the first surface 4a a first interface 40a, wherein the shape of the first interface 40a is defined by the shape of the first surface 4a. The liquid material is solidified by means of UV radiation 8, which is emitted by means of the solidification unit 102 and enters the cavity through the light shield 5, which is transparent to UV radiation 8.

[0169] In subsequent method steps, at least one optical component can be formed by a molding process, wherein the first interface 40a provides at least one surface of the molding die and the shape of the optical surface of the optical component 1 is formed through the first interface 40a.

[0170] As an alternative to method step e1), in method step e2), the optical component includes a rigid material 40 and the first interface 40a is the optical surface of the optical component 1.

[0171] Figure 14a and 14b An exemplary embodiment of a method for producing at least one optical component is illustrated in a schematic cross-sectional view, wherein an additional interface 4c is fabricated.

[0172] like Figure 14a As shown, in method step a1), a cavity 2 is provided. The cavity 2 is demarcated on opposite sides by a first membrane portion 3 and a carrier 9. In particular, the carrier 9 may be an optical element 11, such as a lens, having a curved surface. Alternatively, the carrier 9 may be a planar transparent carrier. A light-shielding plate 5 laterally demarcates the cavity 2. The light-shielding plate 5 includes a spring 53, which laterally demarcates the cavity. The light-shielding plate 5 can be moved in the z-direction to adjust the shape of the first membrane portion 3. The light-shielding plate 5, and in particular the spring 53, provides a flexible, particularly liquid-tight, connection between the sidewall 54 and the first membrane portion 3a.

[0173] Sidewall 54 circumferentially surrounds carrier 9 (along the xy-plane). The carrier is movable along the z-direction. In particular, the carrier is mounted on positioning unit 93, which is arranged to move carrier 9 along the z-axis. Position disassembly may include threads, which enable adjustment of the position of carrier 9.

[0174] In method step b1), liquid material 4 is filled into cavity 2. In method step c1), the shape of the first surface 4a of liquid material 4 is adjusted. In this particular embodiment, the first surface 4a is concave. The shape can be adjusted by changing the relative pressure between cavity 2 and the region opposite to the cavity on the side of the first membrane 3. Alternatively, the shape can be adjusted by moving the light-shielding plate 5 along the z-direction. However, the shape of the first membrane portion 3a can be adjusted by moving the carrier 9 along the z-direction.

[0175] In step d1), the liquid material 4 is solidified, so that the liquid material 4 becomes a rigid material 40 and the first surface 4a becomes a first interface 40a, wherein the shape of the first interface 40a is defined by the shape of the first surface 4a.

[0176] Following method step d1), the position of the carrier 9 is adjusted along the z-direction, wherein the rigid material remains in contact with the carrier 9. Therefore, an additional region 21 is created within the cavity 2, which is demarcated on one side by the first interface 40a.

[0177] like Figure 14b As shown, in subsequent method steps b2), c2), and d2), an additional interface 40c is created. (As...) Figure 14b As shown, in method step b2), additional liquid material 41 is filled into at least one cavity, particularly in additional region 21, wherein the additional liquid material 41 is adjacent to the interface 40a formed in the aforementioned method step d1). In particular, if multiple additional interfaces 40c are formed, the additional liquid 41 may be adjacent to the additional interfaces 40c formed in the aforementioned method step d2).

[0178] In method step c2), the shape of the additional surface 4c of the additional liquid material is adjusted. The additional surface 4c is arranged on one side of the additional liquid material 41, which is opposite to the interfaces 40a, 40c formed in the aforementioned method steps d1) or d2). The shape of the additional surface can be adjusted by the same means as in method step c1).

[0179] In step d2), the additional liquid material is solidified, such that the additional liquid material 41 becomes the additional rigid material 410 and the additional surface 4c becomes the additional interface 40c, wherein the shape of the additional interface 40c is defined by the shape of the additional surface 4c.

[0180] After at least one iteration of methods b2), c2), and d2), the optical component comprises a rigid material 40 and an additional rigid material 410. The first interface 40a and the additional interface 40c are optical surfaces of the optical component. Specifically, the rigid material and the additional rigid material have different refractive indices. The (additional) rigid materials 40a and 40c are arranged adjacent to each other and have different refractive indices, thereby the additional interface 40c forms a refractive interface. In particular, the optical component is an achromatic lens or a highly achromatic lens.

[0181] Figure 15 An exemplary embodiment of a method for producing at least one optical component is illustrated in a schematic cross-sectional view, wherein the shape of the first 4a and / or the second 4b surfaces is measured by a measuring unit 120.

[0182] In method step a1), a cavity 2 is provided, wherein the cavity is defined by a first membrane portion 3 and a second membrane portion 6 on opposite sides of the cavity. A light-shielding plate 5 laterally (along the XY plane) defines the cavity 2.

[0183] In step b1), liquid material 4 is filled into cavity 2 through channel 7. Channel 7 connects cavity 2 and reservoir 55, and includes liquid material 4.

[0184] In method step c1), the shapes of the first surface 4a and the second surface 4b are adjusted. The shapes of the first surface 4a and the second surface 4b are adjusted by adjusting the relative pressure values ​​between the cavity 2 and the regions adjacent to the first membrane portion 3 (pressure P2) and the second membrane portion 6 (pressure P3). In method step c1), the channel 7 may remain open, allowing the liquid material 4 to flow between the cavity 2 and the reservoir 55. In particular, the reservoir 55 and the cavity 55 are at the same pressure value P1. The reservoir 55 may be open to be at ambient pressure. The ratio of P1 to P2 may be defined independently of the ratio of P1 to P3. The shape of the first surface can be controlled independently of the shape of the second surface by adjusting the pressure values ​​P2 and P3, since the cavity 2 maintains a constant pressure value P1. Therefore, changes in the shape of the first or second surface cause the liquid material to flow through the channel 7. Advantageously, adjusting the shape of the first surface does not affect the shape of the second surface, and vice versa.

[0185] The measuring unit is arranged to measure the shape of the first and second surfaces using a measuring beam 123, which propagates through the first surface 4a and the second surface 4b. Alternatively, the measuring unit may be arranged to measure the shape of the first / second surfaces (4a, 4b) using reflections from the first and / or second surfaces. In particular, the measuring unit 120 may include a Sack Hartmann sensor.

[0186] In step d1), the liquid material 4 is solidified by UV radiation 8, transforming the liquid material 4 into a rigid material 40, and the first surface 4a becomes the first interface 40a, and the second surface 4b becomes the second interface 40b. The UV radiation is directed to the cavity by a deflector 81, which can be transparent to the measurement beam. In particular, the measurement beam 120 and the UV radiation 8 extend along a common optical path. Figure 16 An exemplary embodiment of a method for producing at least one optical component is illustrated in schematic cross-sectional view, wherein the shape of a second surface 4b is defined by an actuation unit 101. Specifically, the actuation unit 101 is arranged to define the positions of discrete points of the second surface 4b along the z-axis. The actuation unit 101 includes a plurality of actuators 103 arranged to push against a second membrane portion 6. In particular, the actuators include pins that contact the second membrane portion, wherein the position of the pins along the z-axis is adjustable. The actuators 103 for adjusting the position of the pins along the z-axis can be piezoelectric actuators, voice coil actuators, electro-permanent magnet actuators, stepper motors, or hydraulic actuators.

[0187] During step c1), the pressure P1 of the liquid material 4 remains constant. Specifically, pressure P1 is equivalent to ambient pressure. Therefore, changing the shape of the second surface does not affect the shape of the first surface 4a. The shape of the first surface 4a is adjusted by regulating the relative pressure between P1 and P2.

Claims

1. A method for producing at least one optical component (1), comprising the following steps: a1) provides at least one cavity (2). b1) Fill the at least one cavity (2) with liquid material (4). c1) Adjust the shape of the first surface (4a) of the liquid material (4), d1) The liquid material (4) filled into the at least one cavity (2) is solidified, such that the liquid material (4) becomes a rigid material (40) and the first surface (4a) becomes a first interface (40a), wherein the shape of the first interface (40a) is defined by the shape of the first surface (4a), and either e1) The at least one optical component is formed by a molding process, wherein the first interface (40a) provides at least one surface of the molding die and the shape of the optical surface of the optical component (1) is formed through the first interface (40a), or e2) The optical component includes the rigid material (40) and the first interface (40a) is the optical surface of the optical component (1).

2. The method according to claim 1, wherein In method step a1), the at least one cavity (2) is demarcated on a first side by the surface (3a) of the first membrane portion (3), wherein the shape of the first membrane portion (3) is adjustable; In method step b1), the liquid material (4) is filled into the at least one cavity (2) such that the liquid material (4) contacts the surface (3a) of the first membrane portion (3). In method step c1), the shape of the first surface (4a) of the liquid material is adjusted by adjusting the shape of the first membrane portion (3).

3. The method according to claim 1 or 2, wherein the at least one optical component (1) is a lens and the optical surface is the refractive surface of the lens.

4. The method according to any one of claims 1-3, wherein the at least one cavity (2) is formed by an opening (5a) formed in a light shield (5), wherein the first membrane portion (3) is connected to the light shield (5) and covers the opening (5a) to delineate the at least one cavity (2) on the first side.

5. The method according to claim 4, wherein the light-shielding plate (5) includes at least one channel (7), and the at least one cavity (2) is filled therethrough with the liquid material (4).

6. The method according to claim 4 or 5, wherein after method step d1), the light shield (3) carries the rigid material (40).

7. The method according to any of the preceding claims, wherein the method includes method step e1), wherein the adhesion of the optical component to the first interface (40a) is reduced by means of a coating applied to the first interface (40a) or a film (3) disposed between the first interface (40a) and the optical component (1), or by means of a nanostructure formed by the first interface (40a).

8. The method according to any one of claims 1-6, wherein the method includes method step e2), wherein the reflection of light in the visible wavelength range at the first interface (40a) is reduced by a coating applied to the first interface (40a) or the film (3), or by a nanostructure formed from the first interface.

9. The method according to any one of claims 4-8, wherein the method includes method step e2), and an optical element (11) is provided on one side of the light shield (5), which faces away from the first surface (4a).

10. The method of claim 9, wherein the optical element (11) comprises a refractive index substantially equal to the refractive index of the rigid material (40), and / or the optical element (11) comprises the same material as the rigid material (40).

11. The method according to claim 9 or 10, wherein in method step d1), the optical element (11) is bonded to the rigid material (40).

12. The method according to any one of claims 9-11, wherein the optical element (11) comprises a curved optical surface (11a), and the curved optical surface (11a) faces away from the rigid material (40) filling the at least one cavity (2).

13. The method according to any one of claims 1-8, wherein the method includes method step e2), and wherein the at least one cavity (2) is defined by a surface (6a) of a second membrane portion (6) on a second side opposite to the first side, wherein the shape of the second membrane portion (6) is adjustable. Step b1) further includes filling the at least one cavity (2) with the liquid material (4) such that the liquid material (4) also contacts the surface (6a) of the second membrane portion (6). Step c1) further includes adjusting the shape of the second membrane portion (6). Step d1) further includes solidifying the liquid material (4) filled into the at least one cavity (2) such that the liquid material forms a second interface (40b) of the at least one optical component (1), the second interface (40b) including a shape defined by the shape of the surface (6a) of the second film portion (6).

14. The method according to any of the preceding claims, wherein The method includes method step e2). Step a1) includes providing a carrier (9), specifically for carrying the at least one optical component (1), and The method step d1) further includes removing the carrier (9) from the rigid material (40), or The carrier (9) is fixedly attached to the rigid material (40) and the carrier (90) forms a mounting base for the at least one optical component (1).

15. The method according to claim 14, wherein the carrier (9) is a printed circuit board.

16. The method according to claim 14 or 15, wherein the carrier (9) includes at least one opening (9a), wherein the liquid material (4) is further filled into the at least one opening (9a) of the carrier (9) for connecting the at least one optical component (1) to the carrier (9) in a form-fitting manner in method step d1).

17. The method according to claim 16, wherein the at least one opening (9a) of the carrier (9) forms the aperture of the at least one optical component (1).

18. The method according to claim 14 or 16, wherein the carrier (9) is a transparent carrier comprising a first side (91) facing the liquid material (4), the liquid material being filled into the cavity in method step b1), and a second side (92) facing away from the first side of the carrier (9), wherein The carrier (9) divides the at least one cavity (2) into a first region (2a) extending from the carrier (9) starting from the first side (91), and a second region (2b) extending from the carrier (9) starting from the second side (92), wherein Step b1) further includes filling the at least one cavity (2) with the liquid material (4) such that the liquid material (4) contacts the first side (91) of the carrier (9), and Step d1) further includes curing the liquid material (4) in the first region (2a) such that the rigid material (40) is bonded to the first side (91) of the carrier (9).

19. The method according to claim 18, wherein, The method includes other steps: b2) The liquid material (4) is filled into the second region (2b) of the at least one cavity (2) such that the liquid material contacts the second side (92) of the carrier (9). c2) Adjust the shape of the second surface (4b) of the liquid material (4) in the second region (2b); d2) The liquid material (4) filled into the second region (2b) is solidified, such that the liquid material (4) becomes a rigid material and the second surface (4b) becomes a second interface (40b), wherein the shape of the second interface (40b) is defined by the shape of the second surface (4b), and such that the rigid material (4) is bonded to the second side (92) of the carrier (9). Method steps b2), c2), and d2) are executed in the order listed after method step d1).

20. The method according to any of the preceding claims, wherein method step c1) and / or method step c2) comprises at least one of: - Deform the light-shielding plate (5); - Apply pressure to the light-shielding plate (5) at several points simultaneously; - Adjust the pressure (P1) of the liquid material (4) and / or the ambient pressure (P2, P3) outside the at least one cavity (2); - Inhale or press the first membrane portion (3) into the molding die and / or inhale or press the second membrane portion (6) into the molding die; - Push the master plate toward the first film portion (3) and / or push the master plate toward the second film portion (6); - Change the distance between the first and second portions (51, 52) of the light-shielding plate (5); - Change the distance between the first membrane portion (3) and the second membrane portion (6); - Rotate the liquid material such that the shape of the first (4a) and / or the second (4b) surfaces is at least partially defined by the centrifugal force applied to the liquid material (4).

21. The method according to any of the preceding claims, wherein in method steps c1), c2), d1) and / or d2), the shape of the (4a) and / or the second (4b) surface is measured.

22. The method according to any of the preceding claims, wherein the shapes of the first surface (4a) and / or the second surface (4b) are repeatedly adjusted.

23. The method according to any of the preceding claims, wherein in method step d1) and / or method step d2), the liquid material (4) is irradiated with ultraviolet light (8) to cure.

24. The method according to any of the preceding claims, wherein in method step d1) and / or method step d2), sub-regions of the liquid material (4) of the at least one optical component (1) are successively solidified.

25. The method according to any one of claims 1-22, wherein in method steps d1) and / or d2), the liquid material (4) is heated to solidify.

26. The method according to any one of claims 4-25, wherein the light shield (5) is removed after the liquid material (4) of the at least one optical component (1) has been cured.

27. The method according to any of the preceding claims, wherein In method step a1), multiple cavities (2) are provided. In method step b1), the plurality of cavities (2) are filled with the liquid material (4), wherein for each of the plurality of cavities (2), the liquid material (4) forms a first surface (4a). In method step c1), the shape of the first surface (4a) is adjusted; and In step d1), the liquid material (4) is solidified, so that the liquid material (4) becomes a rigid material (40) and the first surface (4a) becomes a first interface (40a), wherein the shape of the first interface (40a) is defined by the shape of the first surface (4a).

28. The method according to claim 27 or 28, wherein the optical component (1) is a lens array comprising a plurality of lenses, wherein each first interface (40a) defines the shape of the refractive surface of the lens.

29. The method of claim 29, wherein excess material between adjacent lenses, particularly uncured liquid material (4), is removed after the liquid material (4) has been cured.

30. The method of claim 30, wherein in method step f1), the lenses of the lens array are separated by at least one of the following: grinding, laser cutting, stamping, cutting, punching, wherein Method step f1) is executed after method step d1).

31. The method according to any of the preceding claims, comprising method step e2), wherein after method step d1), In method step b2), additional liquid material is filled into the at least one cavity, wherein the additional liquid is adjacent to the interface created in method step d1) or d2). In method step c2), the shape of the additional surface (4c) is adjusted, wherein the additional surface (4c) is disposed on the side of the additional liquid material opposite the interface (40a), which was manufactured in the aforementioned method steps d1) or d2). In method step d2), the additional liquid material is solidified such that the additional liquid material becomes an additional rigid material and the additional surface (4c) becomes an additional interface (40c), wherein the shape of the additional interface (40c) is defined by the shape of the additional surface (4c).

32. An optical device comprising at least one optical component (1) produced using the method according to any of the preceding claims.

33. An optical device, comprising: - Rigid material (40) - A component, at least partially embedded in the rigid material (40), The optical device includes at least one optical surface (1a, 1b) configured to influence the interaction of light with the component in a predefined manner, wherein the at least one optical surface (1a, 1b) is formed by a film portion disposed on the rigid material (40).

34. The optical device according to claim 33, wherein the at least one optical surface (1a, 1b) is formed of one of: the rigid material (40) and a layer disposed on the rigid material (40).

35. The optical device according to claim 33 or 34, wherein the component is fully embedded in the rigid material (4).

36. The optical device according to any one of claims 33-35, wherein the embedded component is one of: an electronic component; an optical component, a diffraction grating, an aperture, a filter, an optoelectronic component, a trim, a sensor, or a light source.

37. The optical device according to any one of claims 33-36, wherein the at least one optical surface (1a, 1b) is formed of the rigid material (4) in a liquid state.

38. An apparatus (100) for producing at least one optical component (1), comprising: - At least one cavity (2) for containing liquid curable material (4). - An actuator unit for defining the shape of the first surface (4a) of the liquid solidifiable material (4) within the cavity (2), and - A curing unit (102), used to cure liquid material (4) when liquid material is in at least one cavity (2), further comprising - A light-shielding plate (5) with an opening (5a). - A first film portion (3), connected to the light shield (5) and covering the opening (5a), to delineate the at least one cavity (2) on a first side, wherein the first film portion (3) includes a surface (3a) for defining the shape of a first interface (1a) of the at least one optical component (1) to be manufactured when the liquid material (4) is filled into the at least one cavity (2) and contacts the surface (3a) of the first film portion (3). - An actuator unit (101) is configured to adjust the shape of the first film portion (3) to adjust the shape of the interface (1a) of the at least one optical component (1), and - Curing unit (102), used to cure the liquid material (4) when the liquid material is filled into the at least one cavity (2).

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