Optical element, optical equipment, system, and optical element manufacturing method

Abstract

To provide technique advantageous for materializing a high-quality optical element.SOLUTION: An optical element comprises: a first molding portion which has a base portion including a first lateral surface; and a second molding portion arranged on the base portion, and having a first portion, second portion and third portion which are consecutive to each other. The third portion is interposed between the first portion and the second portion, and the first portion includes a first optical surface, and a first end surface on a side opposite to a side connected to the third portion, the second portion includes a second optical surface, and a second edge surface on a side opposite to the side connected to the third portion, and the third portion includes a third optical surface. The first molding portion protrudes from the base portion in a first direction relative to the first lateral surface, and has a first protrusion portion and a second protrusion portion which are arranged with mutually spaced intervals, and the second molding portion has a third protrusion portion which protrudes to the first direction from the third portion, and is arranged between the first protrusion portion and the second protrusion portion, wherein the third protrusion portion has a first gate mark.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present disclosure relates to technologies such as optical elements. [Background technology]

[0002] Patent Document 1 discloses a method for manufacturing an optical element by injection molding using a thermoplastic resin. When manufacturing an optical element by injection molding, a mold having a cavity in the shape of the optical element is prepared, molten resin is filled into the mold, and the molten resin is cooled to solidify, thereby obtaining the optical element. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2001-353761 A Summary of the Invention [Problem to be solved by the invention]

[0004] When an optical element becomes thick, a temperature distribution occurs in the molten resin during cooling, and distortion may remain inside the obtained optical element. In addition, depending on the way the molten resin flows inside the mold during injection molding, weld lines may form on the optical surface. Distortion occurring inside the optical element and weld lines occurring on the optical surface lead to a deterioration in the quality of the optical element, such as its optical properties.

[0005] The present disclosure provides an advantageous technique for realizing a high-quality optical element. [Means for solving the problem]

[0006] a first molded portion having a base including a first side surface; and a second molded portion disposed on the base and having a first portion, a second portion, and a third portion that are continuous with each other, the third portion being interposed between the first portion and the second portion such that the first portion and the second portion are spaced apart, the first portion including a first optical surface and a first end face opposite to the side connected to the third portion, the second portion including a second optical surface and a second end face opposite to the side connected to the third portion, the third portion including a third optical surface, the first molded portion having a first protrusion portion and a second protrusion portion that protrude from the base in a first direction relative to the first side surface and are spaced apart from each other, the second molded portion having a third protrusion portion that protrudes from the third portion in the first direction and is disposed between the first protrusion portion and the second protrusion portion, and the third protrusion portion has a first gate mark.

[0007] A second aspect of the present disclosure is a manufacturing method for an optical element, which manufactures an optical element made of resin by insert molding, comprising the steps of: injecting molten resin into a first mold to mold a first molded part having a base including a first side surface; and injecting molten resin into a second mold with the first molded part disposed in the second mold to mold a second molded part disposed on the base and having a first part, a second part, and a third part that are continuous with each other, wherein the third part is interposed between the first part and the second part such that the first part and the second part are spaced apart, and the first part has a first optical surface and a first side opposite to a side connected to the third part. a first end face of the second mold, the second portion including a second optical surface and a second end face opposite to the side connected to the third portion, the third portion including a third optical surface, the first molded portion having a first protrusion and a second protrusion protruding from the base in a first direction relative to the first side surface and spaced apart from each other, the second molded portion having a third protrusion protruding from the third portion in the first direction and arranged between the first protrusion and the second protrusion, and a process of molding the second molded portion includes injecting molten resin into the second mold using a portion corresponding to the third protrusion as a gate. Effect of the Invention

[0008] According to the present disclosure, it is possible to provide an advantageous technique for realizing a high-quality optical element. [Brief description of the drawings]

[0009] [Figure 1] 1A and 1B are perspective views of an optical prism according to a first embodiment. [Diagram 2] 1A is a plan view of the optical prism according to the first embodiment, and FIG.1B is a side view of the optical prism according to the first embodiment. [Diagram 3] 2(a) is a cross-sectional view of the optical prism taken along line II in FIG. 2(a), and FIG. 2(b) is a cross-sectional view of the optical prism taken along line II-II in FIG. 2(a). [Figure 4] 2(a) is a cross-sectional view of the optical prism taken along line III-III in FIG. 2(a), and FIG. 2(b) is a cross-sectional view of the optical prism taken along line IV-IV in FIG. 2(a). [Diagram 5] 3(a) and 3(b) are perspective views of a first molding part according to the first embodiment. [Figure 6] 1A is a plan view of a first molding portion according to the first embodiment, and FIG.1B is a side view of the first molding portion according to the first embodiment. [Figure 7] FIG. 2 is a schematic cross-sectional view for explaining the structure of a mold used in manufacturing a first molded portion according to the first embodiment. [Figure 8] 5(a) to 5(c) are explanatory views of each step of the method for producing a first molded portion according to the first embodiment. [Figure 9] 5(a) to 5(c) are explanatory views of each step of the method for producing a first molded portion according to the first embodiment. [Figure 10] 3 is a schematic cross-sectional view of a mold used to manufacture a second molded portion according to the first embodiment. FIG. [Figure 11] 2 is a schematic cross-sectional view of a fixed core and a movable core according to the first embodiment. FIG. [Figure 12]1A is a perspective view of a portion of a fixed-side mirror piece according to the first embodiment, and FIG. 1B is a cross-sectional view of a portion of a fixed-side mirror piece according to the first embodiment. [Figure 13] 5(a) to 5(c) are explanatory views showing steps of a method for producing a second molded portion according to the first embodiment. [Figure 14] 5(a) to 5(c) are explanatory views showing steps of a method for producing a second molded portion according to the first embodiment. [Figure 15] 5(a) to 5(c) are explanatory views showing steps of a method for producing a second molded portion according to the first embodiment. [Figure 16] 10(a) and (b) are external perspective views of an HMD according to a second embodiment, and (c) is a schematic diagram showing a state in which the HMD is worn by a user. [Figure 17] 10A is a block diagram illustrating the configuration of an HMD according to a second embodiment, and FIG. 10B is a diagram illustrating an MR system according to the second embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] Hereinafter, exemplary embodiments of the present disclosure will be described in detail with reference to the drawings. The following embodiments are illustrative of preferred configurations of the present disclosure, and for example, those skilled in the art can appropriately modify the detailed configurations without departing from the spirit of the present disclosure. In addition, in the drawings referred to in the following description of the embodiments, elements denoted by the same reference numbers have the same functions unless otherwise noted.

[0011] [First embodiment] FIG. 1(a) and FIG. 1(b) are perspective views of the optical prism 1 according to the first embodiment. FIG. 1(a) is a perspective view of the optical prism 1 when the upper surface of the optical prism 1 is viewed obliquely, and FIG. 1(b) is a perspective view of the optical prism 1 when the lower surface of the optical prism 1 is viewed obliquely. FIG. 2(a) is a plan view of the optical prism 1 according to the first embodiment. FIG. 2(b) is a side view of the optical prism 1 according to the first embodiment. FIG. 3(a), FIG. 3(b), FIG. 4(a) and FIG. 4(b) are cross-sectional views of the optical prism 1 according to the first embodiment. FIG. 3(a) is a cross-sectional view of the optical prism 1 taken along line II in FIG. 2(a). FIG. 3(b) is a cross-sectional view of the optical prism 1 taken along line II-II in FIG. 2(a). FIG. 4(a) is a cross-sectional view of the optical prism 1 taken along line III-III in FIG. 2(a). Fig. 4(b) is a cross-sectional view of the optical prism 1 taken along line IV-IV in Fig. 2(a). Here, an orthogonal coordinate system with an X-axis, a Y-axis, and a Z-axis is defined. The X-axis, the Y-axis, and the Z-axis are orthogonal to each other. The X-axis and the Y-axis are in-plane directions parallel to an optical surface 23 described later.

[0012] The optical prism 1 includes a prism body 10, which is an optical element body, and supported parts 51, 52 arranged on both sides of the prism body 10 in the X-axis direction. The prism body 10 is a polyhedron having the function of refracting, dispersing, or totally reflecting light. The supported parts 51, 52 are supported by a support member of an optical device (not shown), whereby the prism body 10 is positioned and fixed at a predetermined position in the optical device. The prism body 10 is thicker than optical lenses such as convex lenses, concave lenses, and aspherical lenses.

[0013] The prism body 10 of the optical prism 1 has at least three optical surfaces and a plurality of non-optical surfaces. In the first embodiment, the prism body 10 includes optical surfaces 21, 22, and 23 and non-optical surfaces 31, 32, 33, 41, and .

[0014] The optical surfaces 21, 22, and 23 are arranged at intervals from one another along the circumferential direction around the X-axis, and the non-optical surfaces 31, 32, and 33 are also arranged at intervals from one another along the circumferential direction around the X-axis. That is, the optical surfaces and the non-optical surfaces are arranged alternately along the circumferential direction. Specifically, the non-optical surface 33 is arranged between the optical surfaces 21 and 23, the non-optical surface 32 is arranged between the optical surfaces 22 and 23, and the non-optical surface 31 is arranged between the optical surfaces 21 and 22. The non-optical surface 41 is arranged on one side in the X-axis direction, and the non-optical surface 42 is arranged on the other side in the X-axis direction.

[0015] The optical surface 21 is an example of a first optical surface and can be used, for example, as an incident surface of a light ray. The light ray irradiated to the optical surface 21 is refracted at the optical surface 21. The optical surface 22 is an example of a second optical surface and can be used as a reflecting surface that totally reflects the light ray inside the prism body 10. The optical surface 23 is an example of a third optical surface and can be used as an exit surface of a light ray. The light ray irradiated to the optical surface 23 is refracted at the optical surface 23. Each of the optical surfaces 21, 22, and 23 is preferably a flat surface. Each of the optical surfaces 21, 22, and 23 is preferably configured as a surface having high flatness with a surface roughness Ra of less than 20 nm. The surface roughness Ra of each of the optical surfaces 21, 22, and 23 can be measured, for example, using a white light interferometer Newview8300 manufactured by ZYGO.

[0016] Non-optical surface 31 is a connecting surface connecting optical surface 21 and optical surface 22. Non-optical surface 32 is a connecting surface connecting optical surface 22 and optical surface 23. Non-optical surface 33 is a connecting surface connecting optical surface 23 and optical surface 21. Non-optical surface 41 is a side surface on the X1 side of prism body 10. Non-optical surface 42 is a side surface on the X2 side, which is opposite non-optical surface 41 of prism body 10.

[0017] The optical surfaces 21, 22, and 23 face in different directions. The optical surfaces 21, 22, and 23 face in directions perpendicular to the X1 and X2 directions (i.e., the X-axis direction), where the X1 and X2 directions are directions along the X-axis, and the X2 direction is a direction opposite to the X1 direction. The X1 direction is an example of a first direction, and the X2 direction is an example of a second direction.

[0018] The supported portion 51 is disposed on the prism body 10 so as to protrude in the X1 direction relative to the non-optical surface 41. The supported portion 52 is disposed on the prism body 10 so as to protrude in the X2 direction relative to the non-optical surface 42.

[0019] The optical prism 1 is made of resin. The optical prism 1 is a resin body integrally molded by insert molding. In the first embodiment, the optical prism 1 includes two molded portions 11 and 12. The molded portion 11 is an example of a first molded portion, and the molded portion 12 is an example of a second molded portion. The molded portion 12 is disposed on the molded portion 11 so as to cover a portion of the molded portion 11.

[0020] In this way, the optical prism 1 is formed by dividing it into two molded portions 11, 12, so that distortion inside the prism body 10 is reduced compared to when the optical prism is molded by a single injection molding. Also, the optical surfaces 21, 22, 23 are formed so as not to include the seam line of the two molded portions 11, 12. In the first embodiment, the optical surfaces 21, 22, 23 are included in the molded portion 12.

[0021] The material of each of the molded parts 11 and 12 is preferably a thermoplastic resin. Among the thermoplastic resins, cycloolefin polymer, cycloolefin copolymer, polycarbonate, or acrylic is preferable. Moreover, the material of the molded part 11 and the material of the molded part 12 are preferably the same.

[0022] The molded portion 11 has a base portion 110, two protruding portions 111 and 112 protruding from the base portion 110 in the X1 direction, and a protruding portion 113 protruding from the base portion 110 in the X2 direction.

[0023] The molding portion 12 has a base 120 disposed on the base 110, and a protruding portion 124 protruding in the X1 direction from the base 120. The base 120 is formed in a substantially C-shape in the circumferential direction around the X-axis so as to partially cover the base 110. The prism body 10 is configured to include the base 110 and the base 120.

[0024] The base 120 has a portion 121 which is an example of a first portion, a portion 122 which is an example of a second portion, and a portion 123 which is an example of a third portion. The protruding portion 124 protrudes from the portion 123 of the base 120 in the X1 direction. When only the molded portion 12 is considered, the portions 121, 122, and 123 are integral and continuous with each other. The portion 123 is interposed between the portions 121 and 122 so that the portions 121 and 122 are spaced apart from each other. In other words, when only the molded portion 12 is considered, the portions 121 and 122 are connected to each other via the portion 123.

[0025] In molded portion 12, portions 121 and 123 may be directly connected, but in the first embodiment, they are connected via connecting portion 125. Also, in molded portion 12, portions 122 and 123 may be directly connected, but in the first embodiment, they are connected via connecting portion 126. That is, in the first embodiment, base 120 has portion 121, connecting portion 125, portion 123, connecting portion 126, and portion 122, and these portions 121 to 126 are integral and continuous with each other.

[0026] In the first embodiment, the supported portion 51 is configured to include the protruding portion 111, the protruding portion 112, and the protruding portion 124. In the first embodiment, the supported portion 52 is configured to include the protruding portion 113. The protruding portion 111 and the protruding portion 112 are arranged at an interval from each other in the Y-axis direction. The protruding portion 124 is arranged between the protruding portion 111 and the protruding portion 112 in the Y-axis direction. The protruding portion 124 is integrated with the protruding portion 111 and the protruding portion 112. Here, the protruding portion 111 is an example of a first protruding portion, the protruding portion 112 is an example of a second protruding portion, the protruding portion 124 is an example of a third protruding portion, and the protruding portion 113 is an example of a fourth protruding portion.

[0027] The base 110 includes a side surface 410 that is a part of the non-optical surface 41, a side surface 420 that is a part of the non-optical surface 42, and a base surface 310 that is a part of the non-optical surface 31. The side surface 420 is the side surface opposite to the side surface 410. The side surface 410 is an example of a first side surface, and the side surface 420 is an example of a second side surface. The base surface 310 is a surface between the side surfaces 410 and 420, and is a surface that intersects with the side surfaces 410 and 420.

[0028] The protrusions 111 and 112 protrude in the X1 direction from the base 110, and therefore protrude in the X1 direction relative to the side surface 410. The protrusion 113 protrudes in the X2 direction from the base 110, and therefore protrudes in the X2 direction relative to the side surface 420.

[0029] The base 120 includes optical surfaces 21 to 23, non-optical surfaces 32 and 33, an end surface 311 that is a part of the non-optical surface 31, an end surface 312 that is a part of the non-optical surface 31, a side surface 411 that is a part of the non-optical surface 41, and a side surface 421 that is a part of the non-optical surface 42. That is, the portion 121 includes the optical surface 21 and the end surface 311. The portion 122 includes the optical surface 22 and the end surface 312. The portion 123 includes the optical surface 23. The end surface 311 is an example of a first end surface, and the end surface 312 is an example of a second end surface. The end surfaces 311 and 312 are circumferential end surfaces of the base 120, and are spaced apart from each other in the circumferential direction.

[0030] The end face 311 is an end face included in the portion 121 of the base 120, is an end face opposite to the side where the portion 121 is connected to the portion 123, and is open to the outside of the optical prism 1. The end face 312 is an end face included in the portion 122 of the base 120, is an end face opposite to the side where the portion 122 is connected to the portion 123, and is open to the outside of the optical prism 1. The base surface 310 is located between the end surfaces 311 and 312, and is a surface that is flush with the end surfaces 311 and 312. In other words, the end faces 311 and 312 are arranged to sandwich the base surface 310, and are flush with the base surface 310.

[0031] From the above, the non-optical surface 31 includes a base surface 310, an end surface 311, and an end surface 312. The non-optical surface 41 includes a side surface 410 and a side surface 411. The non-optical surface 42 includes a side surface 420 and a side surface 421.

[0032] In the first embodiment, the protrusion 124 has a gate mark 61 which is an example of a first gate mark, and the protrusion 113 has a gate mark 62 which is a second gate mark. The gate marks 61, 62 correspond to gates of a mold, and are marks formed when a runner is removed from the optical prism 1. The gate mark 61 is formed on a side surface 1241 of the protrusion 124 facing the X1 direction. The gate mark 62 is formed on a side surface 1131 of the protrusion 113 facing the X2 direction.

[0033] In the first embodiment, the molded portion 12 is disposed so as not to cover the side surface 410 and the side surface 420 of the molded portion 11. In other words, the side surface 410 and the side surface 420 are surfaces exposed from the molded portion 12.

[0034] 2(b), the supported portion 51 has an attachment surface 511 and an attachment surface 512 opposite to the attachment surface 511. The supported portion 51 also has a plurality of side surfaces 513, 514, and 515 intersecting the attachment surface 511 and the attachment surface 512. The side surface 514 is a surface facing the X1 direction and including the side surface 1241 on which the gate mark 61 is formed.

[0035] Molded portion 11 and portion 121 of molded portion 12 are in contact with each other at an interface 801. Molded portion 11 and portion 122 of molded portion 12 are in contact with each other at an interface 802. Molded portion 11 and portion 123 of molded portion 12 are in contact with each other at an interface 803.

[0036] Interface 801 is a flat surface having a similar shape to optical surface 21. Interface 801 and optical surface 21 are parallel to each other. Interface 802 is a flat surface having a similar shape to optical surface 22. Interface 802 and optical surface 22 are parallel to each other. Interface 803 is a flat surface having a similar shape to optical surface 23. Interface 803 and optical surface 23 are parallel to each other.

[0037] Figures 5(a) and 5(b) are perspective views of the molded portion 11 according to the first embodiment. Figure 5(a) is a perspective view of the molded portion 11 when the upper surface of the molded portion 11 is viewed obliquely, and Figure 5(b) is a perspective view of the molded portion 11 when the lower surface of the molded portion 11 is viewed obliquely. Figure 6(a) is a plan view of the molded portion 11 according to the first embodiment. Figure 6(b) is a side view of the molded portion 11 according to the first embodiment.

[0038] The base 110 of the molding portion 11 has main surfaces 81, 82, and 83. Two protrusions 111, 112 are formed in the X1 direction from the base 110, and a protrusion 113 is formed in the X2 direction from the base 110. The protrusion 113 is the supported portion 52. The two protrusions 111, 112 are arranged on the base 110 with a gap therebetween in the Y-axis direction. A recess 63 is defined between the protrusions 111, 112, in which a protrusion 124 having a gate mark 61 is arranged, as shown in FIG. 1(a).

[0039] 3(a) is a cross-sectional view of the optical prism 1 viewed in the X2 direction when the optical prism 1 is cut along a YZ plane (imaginary plane) that intersects with the optical surfaces 21, 22, and 23 and has the X1 direction as its normal direction. The cross-sectional area of ​​the molded portion 11 is S11. The cross-sectional area of ​​the optical prism 1 is S10. In order to sufficiently dissipate the internal strain that occurs in the molded portion 11, which is the primary molded body, during the cooling process of the secondary molding, the cross-sectional area S11 is preferably 40% or more of the cross-sectional area S10, and more preferably 60% or more. The cross-sectional area S11 is preferably larger than the cross-sectional area of ​​the molded portion 12 in this cross section.

[0040] As shown in Fig. 3(a), the cross-sectional shape of the optical prism 1 is substantially trapezoidal. The optical surface 23 and the non-optical surface 31 are flat, and the optical surface 23 and the non-optical surface 31 are parallel to each other. The area S22 of the non-optical surface 31 is smaller than the area S21 of the optical surface 23. That is, as shown in Fig. 2(b), the length L22 in the Y-axis direction of the non-optical surface 31 on the upper base side of the optical prism 1 is shorter than the length L21 in the Y-axis direction of the lower base side of the optical prism 1. The angle θ1 between the optical surface 21 and the optical surface 23 is an acute angle, and the angle θ2 between the optical surface 22 and the optical surface 23 is an acute angle.

[0041] The following describes examples of suitable dimensions for each part. The length L21 of the optical prism 1 in the Y-axis direction shown in Fig. 2(b) is 28.9 mm, and the thickness H21 of the optical prism 1 in the Z-axis direction is 16.0 mm. The length L22 of the non-optical surface 31 in the Y-axis direction is 12.7 mm. The width between the side surface 410 and the side surface 420 in the X-axis direction is 20.0 mm. The width of the optical prism 1 in the X-axis direction is 28.0 mm.

[0042] 6(a) and 6(b), the length L11 in the Y-axis direction of the molded portion 11 is 24.0 mm, and the thickness H11 in the Z-axis direction is 14.0 mm. The length L12 in the Y-axis direction of the base surface 310 of the base portion 110 included in the non-optical surface 31 is 7.7 mm.

[0043] The area S12 of the base surface 310 of the base portion 110 shown in FIG. 2The area S22 of the non-optical surface 31 shown in FIG. 2 In order to prevent warping of the optical prism 1 due to the difference in the resin shrinkage rate between the molded portion 11 and the molded portion 12 during molding, the area S12 of the base surface 310 is preferably 60% or more of the area S22 of the non-optical surface 31, and more preferably 70% or more.

[0044] The thickness in the Z-axis direction of each of the protrusions 111, 112, i.e., the thickness in the Z-axis direction of the supported portion 51, is 4.0 mm. The distance between the optical surface 21 and the interface 801, the distance between the optical surface 22 and the interface 802, and the distance between the optical surface 23 and the interface 803 are all 2.0 mm. The distance in the Y-axis direction between the protrusions 111 and 112, i.e., the length in the Y-axis direction of the protrusion 124, is 6.0 mm, and the width W in the X-axis direction is 5.8 mm. The areas of the side surfaces 410 and 420 are each 220.3 mm 2 It is.

[0045] Although examples of suitable dimensions of the optical prism 1 of the first embodiment have been described above, the dimensions are not limited to those mentioned above.

[0046] Next, a method for manufacturing the optical prism 1 according to the first embodiment will be described. First, a method for manufacturing the molded portion 11, which is the core material (core portion), will be described.

[0047] Fig. 7 is a schematic cross-sectional view for explaining the structure of a mold 601 used in manufacturing the molded portion 11 according to the first embodiment. The mold 601 is an example of a first mold. Fig. 7 illustrates the mold 601 in a clamped state, and a cavity 16 for forming the molded portion 11 is defined inside the clamped mold 601.

[0048] The mold 601 has a fixed side attachment plate 611, a fixed side mold plate 612, a movable side mold plate 613, an ejector plate 614, and a movable side attachment plate 615. The fixed side attachment plate 611, the fixed side mold plate 612, and the movable side mold plate 613 define a runner space 17.

[0049] The fixed side mold plate 612 has a fixed side core 622. The movable side mold plate 613 has a movable side core 623. The fixed side core 622 has a fixed side first forming surface 661 to which the main surface 83, the bottom surfaces of the protruding parts 111 and 112, and the bottom surface of the supported part 52 are transferred. The movable side core 623 has a movable side first forming surface 662 to which the main surfaces 81 and 82, the base surface 310, the side surfaces 410 and 420, the surfaces other than the bottom surfaces of the protruding parts 111 and 112, and the surfaces that define the recess 63 are transferred. The ejector plate 614 has a plurality of ejector pins 624, and the tips of the ejector pins 624 are exposed to the cavity 16 and the runner space 17. The molten resin is injected from the runner space 17 through the gate 663 into the cavity 16.

[0050] Figures 8(a) to 8(c) and 9(a) to 9(c) are explanatory views of each step of the manufacturing method for the molded portion 11 according to the first embodiment. Hereinafter, the manufacturing method for the molded portion 11 using a mold 601 will be described with reference to Figures 8(a) to 8(c) and 9(a) to 9(c).

[0051] First, as shown in Fig. 8(a), molding is started with the mold 601 opened. Next, in the mold clamping process shown in Fig. 8(b), the mold 601 is clamped. At this time, the fixed side mold plate 612 and the movable side mold plate 613 come into contact with each other, and the cavity 16 and the runner space 17 are defined in the mold 601.

[0052] Next, in an injection process shown in FIG. 8(c), molten resin M1 is injected into the cavity 16 through the runner space 17 and the gate 663 by an injection molding machine (not shown).

[0053] 9(a), the temperature of the mold 601 is set to a predetermined temperature lower than the glass transition temperature of the resin, thereby cooling and solidifying the molten resin M1 to form the molded portion 11 and the runner 13. The mold 601 is, for example, of a water-cooled type, and is cooled to a predetermined temperature by water.

[0054] After the molding portion 11 has been sufficiently cooled, the mold 601 is opened in a mold opening step shown in Fig. 9(b). At this time, the molding portion 11 is separated from the fixed-side first molding surface 661 of the fixed-side core 622.

[0055] 9(c), the ejector plate 614 is advanced toward the movable core 623 to project the ejector pins 624 from the movable core 623, and the molded portion 11 is separated from the movable-side first molding surface 662 of the movable core 623. This causes the molded portion 11 and the runner 13 connected to the molded portion 11 to be released from the die 601.

[0056] Thereafter, in a gate cutting process, the runner 13 is separated from the molded portion 11. At this time, a gate mark 62 is formed in the molded portion 11. Through the above-mentioned processes, the molded portion 11 is manufactured.

[0057] Next, a manufacturing method of the molded portion 12 will be described. The molded portion 12 is formed on the molded portion 11. FIG. 10 is a schematic cross-sectional view of a mold 701 used to manufacture the molded portion 12 according to the first embodiment. The mold 701 is an example of a second mold. FIG. 10 illustrates the mold 701 in a clamped state. The molded portion 11 is inserted inside the clamped mold 701, and a cavity 26 for molding the molded portion 12 is defined on the molded portion 11. Note that the molded portion 11 is not illustrated in FIG. 10.

[0058] The mold 701 has a fixed side attachment plate 711, a fixed side mold plate 712, a movable side mold plate 713, an ejector plate 714, and a movable side attachment plate 715. The fixed side attachment plate 711, the fixed side mold plate 712, and the movable side mold plate 713 define a runner space 27.

[0059] The fixed-side mold plate 712 has a fixed-side core 722. The movable-side mold plate 713 has a movable-side core 723. The fixed-side core 722 has a fixed-side second forming surface 761 to which the optical surface 23 is transferred. The movable-side core 723 has a movable-side second forming surface 762 to which the optical surfaces 21 and 22 are transferred. The ejector plate 714 has a plurality of ejector pins 724, and the tips of the ejector pins 724 are exposed to the cavity 26 and the runner space 27. The molten resin is injected from the runner space 27 through the gate 763 into the cavity 26.

[0060] 11 is a schematic cross-sectional view of the fixed core 722 and the movable core 723 according to the first embodiment. The fixed core 722 has a fixed frame piece 2221 and a fixed mirror piece 2222 arranged inside the fixed frame piece 2221. The movable core 723 has a movable frame piece 2231 and a movable mirror piece 2232 arranged inside the movable frame piece 2231.

[0061] The fixed mirror surface piece 2222 and the movable mirror surface piece 2232 are manufactured by coating a zirconia base material with a nickel plating layer, and then precisely machining the nickel plating layer into a shape that transfers the optical surface.

[0062] The thermal conductivity of zirconia is lower than that of metal. By incorporating a zirconia base material into the fixed mirror surface piece 2222 and the movable mirror surface piece 2232, the transferability of the optical surfaces 21, 22, and 23 is improved.

[0063] The following describes the configuration of the fixed mirror piece 2222. Note that the configuration of the movable mirror piece 2232 is similar to that of the fixed mirror piece 2222, so a description of the configuration of the movable mirror piece 2232 will be omitted.

[0064] FIG. 12(a) is a perspective view of a portion of the fixed mirror piece 2222 according to the first embodiment, and FIG. 12(b) is a cross-sectional view of a portion of the fixed mirror piece 2222 according to the first embodiment.

[0065] The zirconia base material 2223 constituting the fixed side mirror surface piece 2222 is a sintered body of zirconia. The zirconia base material 2223 is formed by machining into a shape smaller than the fixed side mirror surface piece 2222 by the thickness of the nickel plating layer 2224.

[0066] The zirconia base material 2223 is plated with nickel to form the nickel plating layer 2224. The thickness of the nickel plating layer 2224 is preferably 5 μm or more to ensure a margin for additional processing. If the thickness of the nickel plating layer 2224 exceeds 500 μm, the transferability of the optical surface may be reduced, or pinholes may be generated in the nickel plating layer 2224. Therefore, the thickness of the nickel plating layer 2224 is preferably 500 μm or less.

[0067] The entire surface of the fixed-side second forming surface 761 is formed of the nickel plating layer 2224. In the side surface 2225 of the fixed-side mirror piece 2222, a portion that is continuous with the fixed-side second forming surface 761 is also formed of the nickel plating layer 2224. In the side surface 2225 of the fixed-side mirror piece 2222, it is preferable that 50 percent or more of the height of the side surface 2225 is the nickel plating layer 2224. In addition, as shown in FIG. 12(b), it is preferable that not only the side surface 2225 but also the mirror piece bottom surface 2226 is formed of the nickel plating layer 2224. In addition, when there is a hole portion 2227 such as a through hole or a screw hole at the bottom of the zirconia base material 2223, it is preferable that the surface of the hole portion 2227 is also formed of the nickel plating layer 2224.

[0068] Since the nickel-plated layer 2224 is disposed on the zirconia base material 2223, electricity can be passed through the nickel-plated layer 2224 to the fixed-side second forming surface 761, and dirt adhering to the fixed-side second forming surface 761 which forms the optical surface 23 can be removed by electrolytic cleaning.

[0069] The base material of the fixed mirror piece 2222 and the movable mirror piece 2232 is not limited to zirconia, and may be selected from materials other than zirconia in consideration of manufacturing costs and material properties. For example, the base material may be an engineering plastic material such as polyimide resin or polybenzimidazole resin, or a metal material such as stainless steel or copper alloy. The material of the plating layer is not limited to nickel, and may be other materials. It is not limited to one layer, and multiple layers may be combined.

[0070] 13(a) to 13(c), 14(a) to 14(c), and 15(a) to 15(c) are explanatory views showing each step of the manufacturing method of the molded portion 12 according to the first embodiment. Note that Fig. 13(a) to Fig. 13(c) show a cross section along the XZ plane of the mold 701 viewed in the positive direction of the Y axis, and Fig. 14(a) to Fig. 14(c) show a cross section along the YZ plane of the mold 701 viewed in the negative direction of the X axis.

[0071] Molding is started from the state where the mold 701 shown in FIG. 13(a) and FIG. 14(a) is opened. Next, the mold clamping process shown in FIG. 13(b) and FIG. 14(b) is performed. The mold clamping process will be described in detail below. First, before the mold 701 is clamped, the molded molding part 11 is heated to a temperature close to that of the mold 701, and the molding part 11 is arranged (inserted) so as to be at a predetermined position with respect to the cavity 26 of the mold 701 which is open. At this time, the molding part 11 is arranged in the mold 701 so that the recess 63 of the molding part 11 and the gate 763 of the mold 701 overlap. Next, the mold 701 is clamped. At this time, the fixed side mold plate 712 and the movable side mold plate 713 come into contact with each other, and the cavity 26 and the runner space 27 are defined with the molding part 11 inserted into the cavity 26 in the mold 701. The protruding portions 111 , 112 and the protruding portion 113 of the molded portion 11 are sandwiched between the fixed core 722 and the movable core 723 , so that the molded portion 11 is accurately positioned within the cavity 26 .

[0072] 13(c) and 14(c), an injection molding machine (not shown) injects molten resin M2 into cavity 26 through runner space 27 and gate 763. The material of molten resin M1 used to form molded portion 11 and the material of molten resin M2 used to form molded portion 12 are the same.

[0073] After the injection of the molten resin M2 is completed in the injection process, the cooling process shown in Fig. 15(a) is carried out. In the cooling process, the temperature of the mold 701 is set to a predetermined temperature lower than the glass transition temperature of the resin, thereby cooling and solidifying the molten resin M2 to form the molded portion 12 and the runner 14. The mold 701 is, for example, a water-cooled type, and is cooled to the predetermined temperature by water.

[0074] After the second molding portion 12 has been sufficiently cooled, the metal mold 701 is opened in a mold opening step shown in Fig. 15(b). At this time, the molding portion 12 is separated from the fixed-side second molding surface 761 of the fixed-side core 722.

[0075] 15(c), the ejector plate 714 is advanced toward the movable core 723 to project the ejector pins 724 from the movable core 723 and separate the second molding portion 12 from the movable-side second molding surface 762 of the movable core 723. This causes the molding portion 12 integrated with the molding portion 11 and the runner 14 connected to the molding portion 12 to be released from the die 701.

[0076] Thereafter, in a gate cutting process, the runner 14 is separated from the molding portion 12 to manufacture the optical prism 1. At this time, a gate mark 61 is formed on the protruding portion 124 of the molding portion 12.

[0077] In this way, in the first embodiment, the optical prism 1 is manufactured by performing injection molding in two separate steps, so that the thickness of the resin body molded by each injection molding can be made thin, and the temperature distribution of the resin body molded by each injection molding can be reduced. Therefore, the density distribution of the resin of the optical prism 1 can be reduced, and internal distortion such as uneven refractive index of light can be reduced.

[0078] In addition, the thickness of the resin body molded by each injection molding can be reduced, so the time required for cooling can be shortened. Since the cooling time increases exponentially as the thickness of the resin body increases, the sum of the time required for injection molding of molded parts 11 and 12 is shorter than the time required if optical prism 1 were to be injection molded in one go. In other words, by manufacturing optical prism 1 through two separate injection moldings, the productivity of optical prism 1 is improved.

[0079] Here, a description will be given of the flow of the molten resin M2 when forming the molded portion 12 in the injection process. As shown in Fig. 13(b) and Fig. 14(b), when the mold 701 is clamped with the molded portion 11 inserted, the cavity 26 is defined as spaces to be filled with the molten resin M2, including a space S1 communicating with the gate 763, a space S2 communicating with the space S1, and spaces S3 and S4 branching off from the space S2.

[0080] The space S1 is a space for forming the protrusion 124 that leads to the gate 763. The space S2 is a space for forming the portion 123. The space S3 is a space for forming the portion 121. The space S4 is a space for forming the portion 122. In the cavity 26, the space S1 is connected to the space S2. In the cavity 26, the space S3 and the space S4 are connected to the space S2.

[0081] In the injection process shown in FIG. 13(c) and FIG. 14(c), when the molten resin M2 is injected from an injection molding machine (not shown) into the mold 701, the molten resin M2 first flows into the space S1 of the recess 63 through the gate 763, and the space S1 is filled with the molten resin M2. Next, the molten resin M2 flows from the space S1 into the space S2, and the space S2 is filled with the molten resin M2. Next, the molten resin M2 is diverted from the space S2 into each of the spaces S3 and S4, and each of the spaces S3 and S4 is filled with the molten resin M2. At this time, the spaces S3 and S4 do not join at a position corresponding to the non-optical surface 31, and the flow path of the molten resin M2 is divided by the base surface 310 of the molding portion 11 inserted into the mold 701, and the flow of the molten resin M2 stops at a position corresponding to the end surface 311 in the space S3 and a position corresponding to the end surface 312 in the space S4. This reduces the occurrence of weld lines on the optical surfaces 21, 22, and 23.

[0082] Furthermore, in the cooling process during the second injection molding, the amount of shrinkage of the molten resin M2 when it is cooled is greater than the amount of shrinkage of the molded portion 11 that is inserted. In the first embodiment, since the side surfaces 410 and 420 of the molded portion 11 are not covered with the molten resin M2 that becomes the molded portion 12, the internal stress in the X-axis direction of the optical prism 1 can be released, and the warping or distortion of the shape of the optical prism 1 can be reduced. In addition, since the molten resin M2 does not flow on the side surfaces 410 and 420, it does not merge with the molten resin M2 flowing on the main surfaces 81 and 82 via the side surfaces 410 and 420, and the formation of weld lines on the optical surfaces 21 and 22 can be reduced. In addition, since the molded portion 12 is divided into the end surfaces 311 and 312 on the non-optical surface 31, with the base surface 310 of the molded portion 11 sandwiched therebetween, the internal stress in the direction along the YZ plane can be released, and the warping or distortion of the shape of the optical prism 1 can be reduced.

[0083] Moreover, since gate 763 can be disposed in recess 63 corresponding to protrusion 124 of supported portion 51, there is greater freedom in designing the arrangement of gate 763. Furthermore, since it is possible to ensure the width and height of gate 763, molten resin M2 filled from gate 763 during molding of molded portion 12 does not immediately solidify at gate 763, and molten resin M2 can be filled into cavity 26 while applying pressure uniformly and without loss to the entire cavity 26, allowing molded portion 12 to be molded with high shape precision.

[0084] As described above, according to the first embodiment, it is possible to provide an advantageous technique for realizing a high-quality optical prism 1.

[0085] In the above embodiment, the material of molded portion 11, i.e., the material of molten resin M1, and the material of molded portion 12, i.e., the material of molten resin M2, are the same as each other, but the present invention is not limited to this and they may be different from each other. In this case, it is preferable that the materials of molded portion 11 and molded portion 12 are selected in consideration of the compatibility of the resin constituting molded portion 11 and the resin constituting molded portion 12.

[0086] In the above embodiment, the optical prism 1 has three optical surfaces 21, 22, and 23, but the present invention is not limited to this, and the optical prism may have four or more optical surfaces. When the optical prism has four or more optical surfaces, it is not necessary to form all of the optical surfaces with the second molding part. It is sufficient that at least three of the four or more optical surfaces are configured with the second molding part. However, in consideration of the shape accuracy of each optical surface, it is preferable that all of the optical surfaces are configured with the second molding part.

[0087] In the above embodiment, the distance between optical surface 21 and interface 801, the distance between optical surface 22 and interface 802, and the distance between optical surface 23 and interface 803 are each 2 mm, but the present invention is not limited to these dimensions. However, in consideration of the shape accuracy of optical surfaces 21 to 23, each distance is preferably 0.5 mm or more and 5 mm or less. In addition, it is preferable that these distances are the same, but they may be different from each other.

[0088] In the above-described embodiment, each of the interfaces 801-803 may be a spherical surface, and each of the optical surfaces 21-23 may be an aspheric surface. Also, each of the interfaces 801-803 may be an aspheric surface, and each of the optical surfaces 21-23 may be a free-form surface. In this way, the interfaces 801-803 and the optical surfaces 21-23 do not have to have similar shapes. In such a case, the distance between the interface and the optical surface varies depending on the position on the optical surface. In consideration of the shape accuracy of the optical surfaces 21-23, it is preferable that the ratio of the maximum value to the minimum value of the distance between the interface and the optical surface is 2 or less.

[0089] [Second embodiment] A second embodiment of the present disclosure will be described. In the following, elements with the same reference symbols as those in the first embodiment will have substantially the same configurations and functions as those described in the first embodiment unless otherwise specified, and differences from the first embodiment will be mainly described.

[0090] As an example of an optical device according to the second embodiment, a head mounted display (hereinafter, referred to as "HMD") equipped with the optical prism of the first embodiment will be described. In the following description, the letters L and R at the end of the reference numerals indicate that the components are optical units for the left and right eyes.

[0091] Fig. 16(a) and Fig. 16(b) are external perspective views of the HMD 1000 according to the second embodiment, seen from different directions. Fig. 16(c) is a schematic diagram showing a state in which the user wears the HMD 1000. Fig. 16(c) shows an optical mechanism included in the HMD 1000 and corresponding to the user's right eye, while an optical mechanism with an L suffix is ​​disposed on the left eye side (not shown).

[0092] The HMD 1000 includes a head mounted unit 1010 for mounting the HMD 1000 on the user's head, an imaging unit 1020 for capturing an image in front of the user's head, and a display unit 1040 for displaying graphics.

[0093] The head mounting unit 1010 is for mounting the HMD 1000 on the user's head, and includes a side mounting unit 1210 , an adjuster 1220 , a length adjustment unit 1230 , a back of the head mounting unit 1240 , and a forehead mounting unit 1250 .

[0094] When a user wears the HMD 1000, the user first puts the HMD 1000 on his / her head with the length adjustment unit 1230 loosened by the adjuster 1220. Then, the user brings the forehead mounting unit 1250 into close contact with the forehead, and then tightens the length adjustment unit 1230 by the adjuster 1220 so that the side mounting unit 1210 and the back mounting unit 1240 are brought into close contact with the side and back of the head, respectively. Note that the head mounting unit 1010 can be of various types, such as a spectacle frame type, a helmet type, etc., in addition to the goggle type shown in Figs. 16(a) to 16(c).

[0095] The imaging unit 1020 is, for example, a digital camera, and includes entrance windows 112L and 112R, imaging sensors 116L and 116R, and optical prisms 117L and 117R. Each of the optical prisms 117L and 117R is the optical prism 1 described in the first embodiment.

[0096] The imaging unit 1020 captures an image in approximately the same direction as the head of a user wearing the HMD 1000 faces, that is, in a direction corresponding to the user's field of vision. Specifically, light incident from the outside of the HMD 1000 through the entrance windows 112L and 112R is guided to the inside of the HMD 1000 by the optical prisms 117L and 117R, and is received and imaged by the imaging sensors 116L and 116R. The optical prisms 117L and 117R are positioned at predetermined positions on the housing 2000 of the HMD 1000 by attaching the supported parts 51 and 52 of the optical prisms 117L and 117R to the housing 2000 of the HMD 1000. The housing 2000 is an example of a support member that supports the optical prisms.

[0097] The display unit 1040 includes screens 110L and 110R, color liquid crystal displays 114L and 114R, and optical prisms 115L and 115R. Each of the optical prisms 115L and 115R is the optical prism 1 described in the first embodiment.

[0098] The display unit 1040 is provided at a position corresponding to the eyeglass lenses of the eyeglasses so as to face the position of the user's eyes. Specifically, the images displayed by the color liquid crystal displays 114L, 114R are guided by the optical prisms 115L, 115R and displayed on the screens 110L, 110R. The optical prisms 115L, 1175 are positioned at predetermined positions of the housing 2000 by attaching the supported portions 51, 52 of the optical prisms 115L, 115R to the housing 2000.

[0099] When the HMD 1000 is a video see-through type, the screens 110L and 110R do not have transparency in principle, and display the display light from the color liquid crystal displays 114L and 114R guided by the optical prisms 115L and 115R as it is. On the other hand, when the HMD 1000 is a glass see-through type, the screens 110L and 110R are configured as so-called half mirrors. That is, the screens 110L and 110R have a certain degree of transparency, and allow the user to optically view the scene in real space. At the same time, the mirrors provided on the front or back surface or embedded inside reflect the display light of the graphics displayed by the color liquid crystal displays 114L and 114R and guided by the optical prisms 115L and 115R toward the user's eyes. That is, in the case of the glass see-through type, the scene in real space and the image (graphics) of the virtual object are optically superimposed on the screens 110L and 110R.

[0100] The output light of the optical prisms 115L, 115R of the display unit 1040 and the input light of the optical prisms 117L, 117R of the imaging unit 1020 coincide with the optical axis of the user's pupil, and the imaging sensors 116L, 116R capture images of the real space in the direction of the user's position and head.

[0101] In the case of a video see-through type HMD, the color liquid crystal displays 114L and 114R display an image in which the video of the real space captured by the image sensors 116L and 116R and the image (graphics) of the virtual object are electrically superimposed (image synthesis). On the other hand, in the case of a glass see-through type HMD, the color liquid crystal displays 114L and 114R display, in principle, only the image (graphics) of the virtual object.

[0102] Fig. 17(a) is a block diagram illustrating the configuration of an HMD 1000 according to the second embodiment. The HMD 1000 further includes a display control unit 130, an imaging control unit 140, a CPU 150, a memory 160, a power supply unit 170, a communication unit 180, and a touch recognition unit 190, which are embedded inside the main body including the head mounting unit 1010 and are not shown in Figs. 16(a) to 16(c).

[0103] The display control unit 130 controls the display of the display unit 1040. For example, it controls the size, position, orientation, color, transparency, and movement and brightness changes associated with changes in the image of the real space of the virtual object image (graphics) to be superimposed (image synthesis) on the image of the real space. The image of the virtual object includes, for example, images of a graphical user interface such as a menu display for inputting user instructions, a keyboard, and the like.

[0104] The imaging control unit 140 performs exposure control, distance measurement control, etc., based on the results of a predetermined calculation process using the imaging data. This performs AF (autofocus) processing, AE (auto exposure) processing, AWB (auto white balance) processing, etc. In addition, if the imaging unit 1020 has a mechanism for inserting and removing an optical filter from the optical path, an anti-shake mechanism, etc., it controls the insertion and removal of the filter, anti-shake, etc., according to the imaging data and other conditions.

[0105] The CPU 150 performs arithmetic processing of the entire HMD 1000. Each process of the second embodiment is realized by executing a program recorded in the memory 160 described later. The memory 160 is composed of a work area and a non-volatile area. The work area in the memory 160 stores programs read from the non-volatile area and constants and variables for system control. Also, image (graphics) data of virtual objects to be displayed superimposed on the real space is stored for display. Also, image data captured by the imaging unit 1020 and A / D converted is stored for the purpose of image analysis, image processing, etc.

[0106] The power supply unit 170 is made up of primary batteries such as alkaline batteries or lithium batteries, secondary batteries such as NiCd batteries, NiMH batteries, or Li batteries, an AC adapter, or the like, and supplies power to the entire HMD 1000. The power supply unit 170 also includes a power switch that switches the power on and off according to a user's operation or other conditions. The communication unit 180 communicates with information terminals such as PCs and networks such as LANs and the Internet under the control of the CPU 150.

[0107] The touch recognition unit 190 recognizes a touch operation by a user on an actual object. The touch recognition unit 190 is realized in software, for example, by the CPU 150 performing arithmetic processing on the captured image of the imaging unit 1020 based on a touch recognition program stored in the memory 160. Alternatively, in the case of a method of measuring a change in capacitance, which will be described later, the touch recognition unit 190 is configured by a capacitance measuring meter or the like.

[0108] The HMD 1000 according to the second embodiment includes optical prisms 115L, 115R, 117L, and 117R having the same configuration as the optical prism 1 described in the first embodiment. These optical prisms 115L, 115R, 117L, and 117R have small internal distortion and no weld lines formed on their optical surfaces, so that the HMD 1000 can capture and display images with high image quality. Note that the arrangement and number of the optical prisms according to the first embodiment when mounted on the HMD are not limited to the example of the HMD 1000 of the second embodiment, and can be changed as appropriate.

[0109] An MR system (Mixed Reality System) equipped with a video see-through type HMD 1000 according to the second embodiment will be described with reference to FIG. 17(b).

[0110] As shown in FIG. 17(b), the MR system according to the second embodiment includes an HMD 1000, which is an example of a head-mounted display device, a computer device 1103 that generates an image of a mixed reality space (a space that combines real space and virtual space) to be displayed on the HMD 1000, and a controller 1102 that mediates between the HMD 1000 and the computer device 1103.

[0111] The HMD 1000 includes an imaging unit 1020 that captures an image of a real space, a sensor that measures (measurement processing) the position and orientation of the HMD 1000 itself, and a display unit 1040 that displays an image of the mixed reality space transmitted from an image processing device 104. The HMD 1000 also functions as a synchronization control device for these multiple devices. The HMD 1000 transmits to the controller 102 an image captured by the imaging unit and the position and orientation of the HMD 1000 itself measured by the sensor. The HMD 1000 also receives an image of the mixed reality space generated by a computer device 1103 based on the captured image and the position and orientation from the controller 1102, and displays the image on the display unit. As a result, an image of the mixed reality space is presented in front of the eyes of a user wearing the HMD 1000 on his head.

[0112] The HMD 1000 may operate on power supplied from the controller 1102, or may operate on power supplied from a battery included in the HMD 1000. In other words, the method of supplying power to the HMD 1000 is not limited to a specific method. In FIG. 17(b), the HMD 1000 and the controller 1102 are connected by wire. However, the connection between the HMD 1000 and the controller 1102 is not limited to a wired connection, and may be wireless, or may be a combination of wireless and wired. In other words, the connection between the HMD 1000 and the controller 1102 is not limited to a specific connection.

[0113] Next, the controller 1102 will be described. The controller 1102 performs various image processing (resolution conversion, color space conversion, distortion correction of the optical system of the imaging unit of the HMD 1000, encoding, etc.) on the captured image transmitted from the HMD 1000. The controller 1102 then transmits the processed captured image and the position and orientation transmitted from the HMD 1000 to the computer device 1103. The controller 1102 also performs similar image processing on the image in the mixed reality space transmitted from the computer device 1103 and transmits it to the HMD 1000.

[0114] Next, the computer device 1103 will be described. The computer device 1103 obtains the position and orientation of the HMD 1000 (the position and orientation of the imaging unit of the HMD 1000) based on the captured image and position and orientation received from the controller 1102, and generates an image of the virtual space seen from a viewpoint having the obtained position and orientation. The computer device 1103 then generates a composite image (image of mixed reality space) of the image of the virtual space and the captured image transmitted from the HMD 1000 via the controller 1102, and transmits the generated composite image to the controller 1102. Note that in the figure, the computer device 1103 and the controller 1102 are separate devices, but the computer device 1103 and the controller 1102 may be integrated.

[0115] The MR system according to the second embodiment includes an HMD 1000. The HMD 1000 has an optical prism with small internal distortion and no weld line on the optical surface, so that it can capture and display images with high image quality. Therefore, the MR system according to the second embodiment can provide a user with a high-quality mixed reality space in which the real space and the virtual space are fused together. Note that the method of mounting the HMD 1000 in the MR system is not limited to the example shown in FIG. 17(b) and can be changed as appropriate. Also, the target in which the HMD 1000 is mounted is not limited to an MR system, and may be, for example, an AR system (Augmented Reality System), a VR system (Virtual Reality System), or other systems.

[0116] [Other embodiments] The above-described embodiments may be modified as appropriate without departing from the scope of the technical concept. For example, a plurality of embodiments may be combined. In addition, some of the features of at least one embodiment may be deleted or replaced.

[0117] As is clear from the above description, the present disclosure provides a technology that can suppress deterioration of optical performance due to distortion or welding, and therefore can be implemented in resin optical elements other than optical prisms. The optical prism may be a pentaprism for a single-lens reflex camera or a prism in a viewfinder optical system for a mirrorless camera. For example, the present disclosure may be implemented in an optical element such as a resin lens having multiple optical surfaces and multiple non-optical surfaces, or a manufacturing method thereof. The present disclosure may also be implemented as an optical device including such an optical element, or a system including an optical device.

[0118] In addition, new matters may be added to at least one embodiment. The disclosure of this specification includes not only what is explicitly described in this specification, but also all matters that can be understood from this specification and the drawings attached to this specification.

[0119] Furthermore, the disclosure of this specification includes the complement of each concept described in this specification. In other words, if this specification contains a statement that "A is greater than B," for example, even if the statement that "A is not greater than B" is omitted, this specification can be said to disclose that "A is not greater than B." This is because when a statement that "A is greater than B" is made, it is assumed that the case in which "A is not greater than B" is taken into consideration.

[0120] The disclosure of the above embodiments includes the following sections.

[0121] (Section 1) An optical element made of resin, a first molded portion having a base including a first side; a second molded portion disposed on the base portion and having a first portion, a second portion, and a third portion that are continuous with each other; the third portion is interposed between the first portion and the second portion such that the first portion and the second portion are spaced apart from each other; the first portion includes a first optical surface and a first end surface opposite to a side connected to the third portion, the second portion includes a second optical surface and a second end surface opposite to the side connected to the third portion, the third portion includes a third optical surface; the first molded portion has a first protruding portion and a second protruding portion that protrude from the base portion in a first direction relative to the first side surface and are spaced apart from each other; the second molding portion has a third protruding portion protruding in the first direction from the third portion and disposed between the first protruding portion and the second protruding portion, The third protrusion has a first gate mark. An optical element characterized by:

[0122] (Section 2) the base includes a second side opposite the first side; The second molding portion is arranged so as not to cover the first side surface and the second side surface. 2. The optical element according to item 1,

[0123] (Section 3) the base includes a second side opposite the first side; the first molded portion has a fourth protruding portion protruding from the base portion in a second direction opposite to the first direction with respect to the second side surface of the base portion, The fourth protrusion has a second gate mark. 3. The optical element according to item 1 or 2,

[0124] (Section 4) the first optical surface, the second optical surface, and the third optical surface face in different directions from each other; 4. The optical element according to any one of items 1 to 3.

[0125] (Section 5) the first optical surface, the second optical surface, and the third optical surface are oriented in a direction perpendicular to the first direction; 5. The optical element according to any one of items 1 to 4.

[0126] (Section 6) each of the first optical surface, the second optical surface, and the third optical surface is a flat surface; 6. The optical element according to any one of items 1 to 5,

[0127] (Section 7) an angle between the first optical surface and the third optical surface is an acute angle, the angle between the second optical surface and the third optical surface is an acute angle; 7. The optical element according to item 6,

[0128] (Section 8) when the optical element is cut along a virtual plane that intersects with the first optical surface, the second optical surface, and the third optical surface and has the first direction as a normal direction, a cross-sectional area of ​​the first molded portion is 40% or more of a cross-sectional area of ​​the optical element. 8. The optical element according to any one of items 1 to 7,

[0129] (Section 9) the base portion is located between the first end surface and the second end surface and has a base surface that is flush with the first end surface and the second end surface; A non-optical surface including the first end surface, the second end surface, and the base surface is configured. 9. The optical element according to any one of items 1 to 8,

[0130] (Section 10) The area of ​​the base surface is 60% or more of the area of ​​the non-optical surface. 10. The optical element according to item 9,

[0131] (Section 11) the area of ​​the base surface is 70% or more of the area of ​​the non-optical surface; 10. The optical element according to item 9,

[0132] (Section 12) the third optical surface is a flat surface; the non-optical surface is a planar surface; the non-optical surface and the third optical surface are parallel to each other; Item 12. The optical element according to any one of items 9 to 11,

[0133] (Section 13) The area of ​​the non-optical surface is smaller than the area of ​​the third optical surface. Item 13. The optical element according to any one of items 9 to 12,

[0134] (Section 14) The material of the first molding portion and the material of the second molding portion are the same. Item 14. The optical element according to any one of items 1 to 13,

[0135] (Section 15) The optical element is a prism. Item 15. The optical element according to any one of items 1 to 14.

[0136] (Section 16) The optical element according to any one of items 1 to 15, A support member for supporting the optical element; An optical instrument comprising:

[0137] (Section 17) At least two of the optical elements are provided. Item 17. The optical instrument according to item 16, characterized in that

[0138] (Section 18) The optical device is a head mounted display. Item 18. The optical instrument according to item 17, characterized in that

[0139] (Section 19) Item 17 or 18 includes an optical device according to the present invention and a computer device that generates an image of a virtual space. A system characterized by:

[0140] (Section 20) A method for manufacturing an optical element by insert molding, comprising the steps of: A step of injecting molten resin into a first mold to mold a first molded part having a base including a first side surface; and injecting molten resin into a second mold while the first molded part is disposed in the second mold, thereby forming a second molded part that is disposed on the base and has a first portion, a second portion, and a third portion that are continuous with each other. the third portion is interposed between the first portion and the second portion such that the first portion and the second portion are spaced apart from each other; the first portion includes a first optical surface and a first end surface opposite to a side connected to the third portion, the second portion includes a second optical surface and a second end surface opposite to the side connected to the third portion, the third portion includes a third optical surface; the first molded portion has a first protruding portion and a second protruding portion that protrude from the base portion in a first direction relative to the first side surface and are spaced apart from each other; the second molding portion has a third protruding portion protruding in the first direction from the third portion and disposed between the first protruding portion and the second protruding portion, In the step of molding the second molded portion, a molten resin is injected into the second mold using a portion corresponding to the third protruding portion as a gate. A method for producing an optical element comprising the steps of: [Explanation of symbols]

[0141] 1...optical prism (optical element), 11...molded portion (first molded portion), 12...molded portion (second molded portion), 61...gate mark (first gate mark), 62...gate mark (second gate mark), 111...protruding portion (first protruding portion), 112...protruding portion (second protruding portion), 121...portion (first portion), 122...portion (second portion), 123...portion (third portion), 124...protruding portion (third protruding portion)

Claims

1. An optical element made of resin, a first molded portion having a base including a first side; a second molded portion disposed on the base portion and having a first portion, a second portion, and a third portion that are continuous with one another; the third portion is interposed between the first portion and the second portion such that the first portion and the second portion are spaced apart from each other; the first portion includes a first optical surface and a first end surface opposite to a side connected to the third portion, the second portion includes a second optical surface and a second end surface opposite to a side connected to the third portion, the third portion includes a third optical surface; The first molded portion has a first protruding portion and a second protruding portion that protrude from the base portion in a first direction relative to the first side surface and are spaced apart from each other, the second molding portion has a third protruding portion protruding in the first direction from the third portion and disposed between the first protruding portion and the second protruding portion, The third protrusion has a first gate mark. An optical element characterized by:

2. the base includes a second side opposite the first side; The second molding portion is arranged so as not to cover the first side surface and the second side surface.

2. The optical element according to claim 1 .

3. the base includes a second side opposite the first side; the first molded portion has a fourth protruding portion protruding from the base portion in a second direction opposite to the first direction with respect to the second side surface of the base portion, the fourth protrusion has a second gate mark; 2. The optical element according to claim 1 .

4. the first optical surface, the second optical surface, and the third optical surface face in different directions from each other; 2. The optical element according to claim 1 .

5. the first optical surface, the second optical surface, and the third optical surface are oriented in a direction perpendicular to the first direction; 2. The optical element according to claim 1 .

6. each of the first optical surface, the second optical surface, and the third optical surface is a flat surface; 2. The optical element according to claim 1 .

7. an angle between the first optical surface and the third optical surface is an acute angle, an angle between the second optical surface and the third optical surface is an acute angle; 7. The optical element according to claim 6.

8. when the optical element is cut along a virtual plane that intersects with the first optical surface, the second optical surface, and the third optical surface and has the first direction as a normal direction, a cross-sectional area of ​​the first molded portion is 40% or more of a cross-sectional area of ​​the optical element.

2. The optical element according to claim 1 .

9. the base portion is located between the first end surface and the second end surface and has a base surface that is flush with the first end surface and the second end surface; A non-optical surface including the first end surface, the second end surface, and the base surface is configured.

2. The optical element according to claim 1 .

10. an area of ​​the base surface is 60% or more of an area of ​​the non-optical surface; 10. The optical element according to claim 9.

11. an area of ​​the base surface is 70% or more of an area of ​​the non-optical surface; 10. The optical element according to claim 9.

12. the third optical surface is a flat surface; the non-optical surface is a planar surface; the non-optical surface and the third optical surface are parallel to each other; 10. The optical element according to claim 9.

13. The area of ​​the non-optical surface is smaller than the area of ​​the third optical surface.

10. The optical element according to claim 9.

14. The material of the first molding portion and the material of the second molding portion are the same.

2. The optical element according to claim 1 .

15. The optical element is a prism.

2. The optical element according to claim 1 .

16. The optical element according to any one of claims 1 to 15, A support member for supporting the optical element; An optical instrument comprising:

17. At least two of the optical elements are provided.

17. Optical instrument according to claim 16.

18. The optical device is a head mounted display.

18. Optical instrument according to claim 17.

19. The optical device according to claim 17 and a computer device that generates an image of a virtual space. A system characterized by:

20. A method for manufacturing an optical element by insert molding, comprising the steps of: A step of injecting molten resin into a first mold to mold a first molded part having a base including a first side surface; and a step of injecting molten resin into a second mold while the first molded part is disposed in the second mold, thereby molding a second molded part that is disposed on the base and has a first part, a second part, and a third part that are continuous with each other, the third portion is interposed between the first portion and the second portion such that the first portion and the second portion are spaced apart from each other; the first portion includes a first optical surface and a first end surface opposite to a side connected to the third portion, the second portion includes a second optical surface and a second end surface opposite to a side connected to the third portion, the third portion includes a third optical surface; The first molded portion has a first protruding portion and a second protruding portion that protrude from the base portion in a first direction relative to the first side surface and are spaced apart from each other, the second molding portion has a third protruding portion protruding in the first direction from the third portion and disposed between the first protruding portion and the second protruding portion, In the step of molding the second molded portion, a molten resin is injected into the second mold using a portion corresponding to the third protruding portion as a gate. A method for producing an optical element comprising the steps of:

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