Rapid prototyping of optical components, especially lenses, for manufacturing customized optical surface shapes.

Abstract

A method for manufacturing optical components such as lenses relatively quickly and cost-effectively, while simultaneously ensuring sufficient optical quality. [Solution] The method includes the following steps: a) providing at least one cavity (2), wherein the at least one cavity (2) is partitioned by a first surface (3a) of a first film portion (3), and the shape of the first film portion (3) is adjustable; b) filling the at least one cavity (2) with the material (4) to form at least one optical component (1) such that the material (4) is in contact with the surface (3a) of the first film portion (3); c) adjusting the shape of the first film portion (3); and d) curing the material (4) filled in 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).

Description

Technical Field

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[0001] The present invention relates to a method for manufacturing at least one optical component. Furthermore, the present invention relates to an optical device comprising at least one optical component manufactured by the method according to the present invention. Furthermore, the present invention relates to an optical device having a customized optical surface and a device that can be used to implement the method according to the present invention.

Background Art

[0002] Regarding the manufacture of optical components, especially lenses, it is often difficult to ensure high optical quality while simultaneously shaping each component in an efficient and sufficiently fast manner. In particular, using conventional molds requires a relatively long lead time corresponding to the time from determining the shape of the component until it is completed, and thus takes a relatively long time. Furthermore, established processes such as grinding / 3D milling are relatively expensive and time-consuming. Furthermore, rapid prototyping based on 3D printing is fast and cost-effective, but in most cases, especially when applied to lenses, the quality is inferior.

Summary of the Invention

Problems to be Solved by the Invention

[0003] From the above, the problem to be solved by the present invention is to provide a method that can manufacture optical components such as lenses relatively quickly and cost-effectively while simultaneously ensuring sufficient optical quality.

Means for Solving the Problems

[0004] A method for manufacturing at least one optical component, comprising the following steps: a1) providing at least one cavity (2); b1) filling the at least one cavity (2) with a liquid material (4); c1) adjusting the shape of a first surface (4a) of the liquid material (4); d1) A step of hardening the liquid material (4) filled in the 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 any of the following steps, e1) A step of forming the at least one optical component by a molding process, wherein the first interface (40a) provides at least one surface of a mold, and the shape of the optical surface of the optical component (1) is formed by the first interface (40a), or e2) The optical component comprises the rigid material (40), and the first interface (40a) is the optical surface of the optical component (1). Includes. [Brief explanation of the drawing]

[0005] [Figure 1] Figure 1 is a schematic diagram showing one embodiment of the method according to the present invention for manufacturing an optical component having a customized optical surface. [Figure 2] Figure 2 shows an embodiment of adjusting the film portion for shaping the optical surface. [Figure 3] Figure 3 shows a further embodiment of the method according to the present invention, which uses a mask having channels for applying a liquid material to form an optical component(s). [Figure 4] Figure 4 shows a further embodiment of the method according to the present invention, which uses a carrier to partition cavities used to form optical components in a two-stage curing process. [Figure 5] Figure 5 shows a further embodiment of the method according to the present invention, which uses an optical element to which rigid materials are joined during hardening. [Figure 6] Figure 6 shows a further embodiment of the method according to the present invention, which uses an optical element to which rigid materials are joined during hardening. [Figure 7]Figure 7 shows a further embodiment of the method according to the present invention, in which the optical surface of an optical component is formed by adjusting the pressure P1 of the liquid material relative to the ambient pressures P2 and P3. [Figure 8] Figure 8 shows a further embodiment of the method according to the present invention, in which the optical surface of the optical component is formed with the help of gravity-affected molding fluids L1 and L2. [Figure 9] Figure 9 shows a further embodiment of the method according to the present invention using a carrier on which rigid materials are bonded during curing, where the carrier forms an aperture of an optical component. [Figure 10] Figure 10 shows a further embodiment of the method according to the present invention for manufacturing optical components that form a prism. [Figure 11] Figure 11 is a top view of a device for carrying out the method according to the present invention. [Figure 12] Figure 12 is a cross-sectional view of a device for carrying out the method according to the present invention. [Figure 13] Figure 13 shows a schematic cross-sectional view of an exemplary embodiment of a method for manufacturing at least one optical component, where the shape of the first surface is defined by a piston. [Figure 14ab] Figures 14a and 14b show schematic cross-sectional views of exemplary embodiments of a method for manufacturing at least one optical component, where further interfaces are created. [Figure 15] Figure 15 shows a schematic cross-sectional view of an exemplary embodiment of a method for manufacturing at least one optical component, where the shape of the first and / or second surface is measured by a measuring unit. [Figure 16] Figure 16 shows a schematic cross-sectional view of an exemplary embodiment of a method for manufacturing at least one optical component, where the shape of the second surface is defined by the actuation unit 101. [Modes for carrying out the invention]

[0006] In step a1) of the method, at least one cavity is provided. Hereinafter, and thereafter, a cavity is a sealed space partitioned by one or more solid structures. The solid structures may be elastically deformable, and the deformation of the solid structures is controllable. Thus, the shape of the cavity may be adjustable. The cavity is configured to hold a liquid. The cavity may be configured to completely partition the liquid on all sides. In particular, the cavity is sealed liquid-tight. Alternatively, the cavity may be open to allow the flow of liquid through the cavity. For example, the cavity may be equipped with a valve, which is configured to control the inflow and outflow of liquid into the cavity. The cavity may be configured to move the liquid within the cavity in a predetermined manner by pumping, convection, or by tilting or rotating the cavity.

[0007] In step b1) of the method, the liquid material is filled into at least one cavity. 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 configured to partition the liquid material on at least one side. According to the first alternative embodiment, the cavity may be completely filled with the liquid material. According to the second alternative embodiment, the cavity is partially filled with the liquid material, and furthermore, the cavity is filled with a fluid (gas or liquid) where the fluid and the liquid material are immiscible or have different densities. Thus, the liquid material and the fluid are separated within the cavity.

[0008] According to one embodiment, the liquid material may be provided on a carrier, in step b1) of the method, the carrier is placed in a cavity, or a solid structure partitioning the cavity comprises the carrier. In particular, the liquid material is placed on the surface of the carrier, which is curved and has nanostructures, protrusions, and / or recesses. In particular, the carrier is a wafer, preferably containing silicon, ceramic, or glass.

[0009] In particular, the cavity is open on a further side, and on this further side, the liquid material is adjacent to a fluid (gas or liquid) material. In particular, the fluid material may be at atmospheric pressure.

[0010] A reservoir containing the liquid material may be connected to the cavity. The cavity may include an opening through which the liquid material flows into and out of the cavity. In particular, the flow of the liquid material within the cavity can be continuously controlled. In particular, the liquid material is fed so as to circulate the liquid material within the cavity or to flow the liquid material through the cavity, and the movement of the liquid material becomes more than convection.

[0011] In step b2) of the method, which is executed after step b1) of the method, the cavity can be closed. Accordingly, the opening through which the liquid material fills the cavity can be closed. In particular, by disposing a flexible film on the first surface formed by the liquid material, the cavity is closed when the flexible film is adjacent to the liquid material. For example, a small region of the liquid material can be cured, whereby the liquid material becomes hard in that small region, closing the cavity.

[0012] In step c1) of the method, the shape of the first surface of the liquid material is adjusted. The first surface may be adjacent to the fluid material. The shape of the first surface can be adjusted by controlling the contact angle of the liquid material with respect to the structure partitioning the cavity. The shape of the first surface can be controlled by a continuous airflow that locally applies pressure to the first surface. [[ID=~13]]

[0013] In particular, in step c1) of the method, the volume of the cavity is adjusted. For example, the cavity is connected to a reservoir containing a liquid material. When adjusting the shape of the first surface, 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. By adjusting the volume of the cavity, the shape of the first surface can be adjusted. In particular, the first / second membrane portions may have non-uniform rigidity. In particular, when the shape of the first / second membrane portions changes due to different pressures on the opposite sides of the membrane, the first / second membrane portions are formed into an aspherical shape. The rigidity of the first / second membrane portions may be anisotropic. In particular, the first / second membrane portions may have non-uniform thickness, whereby the rigidity of the first / second membrane portions becomes non-uniform.

[0014] In step d1) of the method, the liquid material is cured such that the liquid material becomes a rigid material and the first surface becomes the first interface, where the first interface has essentially the same shape as the first surface defined in step c1) of the method. Here, and hereinafter, the rigid material has a minimum viscosity of 100000 mPa·s, preferably a minimum viscosity of 1000000 mPa·s, and very preferably a minimum viscosity of 10000000 mPa·s.

[0015] For example, the liquid material is cured by UV radiation, and the UV radiation is applied to small regions of the liquid material. The liquid material is thermally curable, 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 small regions are sequentially exposed to UV radiation.

[0017] In particular, UV radiation is applied in a manner that avoids the inclusion of liquid material in already cured rigid material during curing. For example, a small central region of the liquid material is exposed first, and then smaller regions surrounding that central region are sequentially exposed. Advantageously, mechanical stress, cracks, and bubbles in the rigid material are reduced. For example, UV radiation is applied starting from a central region, and the subsequently exposed regions are arranged radially around the central region. For example, UV radiation is applied in a spot pattern, and the diameter of the spot is progressively increased. The shape, position, and size of the spot can be controlled by variable optical components such as a tunable lens, a tunable mirror, or a tunable prism.

[0018] The liquid material may be cured in a layered manner, in which layers of the liquid material are cured sequentially. In particular, these layers have a principal extending direction perpendicular to the optical axis of the optical component. Specifically, the layer containing the first surface and / or second surface is the last layer to be cured.

[0019] In particular, the cavity includes a compensation region, or the compensation region is adjacent to the cavity. This compensation region is in liquid connection with the portion of the liquid material that is cured during step d1) of the method. The compensation region is variable in volume so that changes in the volume of the liquid material in the cavity during curing are compensated by changes in the volume of the compensation region. In particular, the compensation region may be designed to open to the surrounding environment so that changes in the volume within the compensation region are compensated by ambient air flowing through the compensation region.

[0020] According to one embodiment, the shape of a first surface is changed while a liquid material is cured. For example, a first small region of the liquid material is cured to become a rigid material, while the liquid material in other small regions within the cavity remains uncured. Before further small regions of the liquid material are cured, the position of the rigid material within the cavity is manipulated to change the shape of the first surface. For example, after the first small region is exposed to UV radiation, a pin pushes the rigid material to change its position, thereby altering the shape of the first surface.

[0021] In particular, the temperature of the solid structure sealing the cavity and / or the fluid material within the cavity is controlled. Specifically, by controlling the temperature of the liquid material within the cavity, the curing of the liquid material can be locally initialized, delayed, or accelerated. In particular, the temperature distribution within the liquid material is monitored while the liquid material is curing in step d1) of the method.

[0022] In step e1) of the method, according to the first alternative embodiment, the optical component is manufactured by a molding process, and the mold comprises the rigid material. In particular, the mold defines the shape of the optical component, where the first interface defines the shape of the optical surface of the optical component. In the molding process, the first interface is adjacent to the optical component to be manufactured. The first interface gives rise to a corresponding portion (half) of the optical surface of the optical component.

[0023] The rigid material may be opaque to electromagnetic waves in the visible wavelength range. Advantageously, the rigid material can be optimized with respect to its adhesive and mechanical properties, and its optical properties can be ignored. Therefore, step e1) of the method means there are few constraints on the material selection of the rigid material.

[0024] In step e2) of the method, according to a second alternative embodiment, the optical component comprises a rigid material. In particular, the optical component is made of a rigid material. The first interface comprises the optical surface of the optical component. The optical component may be a refractive optical component, which is configured to interact with light by providing a shape and a specialized change in refractive index specific to the optical surface. In particular, the rigid material is essentially transparent to the light. Alternatively, the optical component may be a reflective optical component, which is configured to reflect electromagnetic waves in a specialized wavelength range. In particular, metallization may be applied to the first interface so as to provide the reflectivity of the optical surface. The metallization and shape of the first interface can define the optical properties of the optical surface. In particular, the rigid material may be opaque to electromagnetic waves that are expected to interact with the optical component.

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

[0026] In particular, the curing of the liquid material may be controlled so that after step d1) of the method, the layer of liquid material is adjacent to the rigid material. In particular, such a layer of liquid material can be placed between the solid structure that partitions the cavity and the rigid material, making it easier to release the rigid material from the cavity. In particular, after curing in step d1) of the method, the liquid material is removed from the cavity, preferably before the rigid material is released from the cavity.

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

[0028] According to one embodiment, after step d1) of the method, the rigid material is post-treated in step f3) of the method. For example, this post-treatment is: - Exposing rigid materials to UV radiation; - Tempering rigid materials; - Coating rigid materials with scratch-resistant coatings, optical filter coatings, anti-reflective coatings, or reflective coatings; - Exposing a rigid material to a vacuum; It includes at least one of the following.

[0029] In particular, post-processing may include processing the edge regions of the rigid material. The edge regions are the parts of the rigid material that define the outer contour of the rigid material, as seen in the top view of the first interface. Processing of the edge regions may include additional processes such as blackening or coating of the edge regions. Processing of the edge regions may include transformation processes such as oxidation or plasma treatment of the edge regions. Processing of the edge regions may include subtractive processes, such as etching, milling, punching, or cutting, to remove a portion of the rigid material.

[0030] According to one embodiment, In step a1) of the method, at least one cavity (2) is partitioned by a first surface (3a) of a first membrane portion (3), where the shape of the first membrane portion (3) is adjustable; In step b1) of the method, the liquid material (4) is filled into at least one cavity (2) such that the liquid material (4) is in contact with the surface (3a) of the first membrane portion (3); In step c1) of the method, the shape of the first surface (4a) of the liquid material is adjusted by adjusting the shape of the first film portion (3).

[0031] According to one embodiment, a method for manufacturing at least one optical component, comprising the following steps: a1) A step of providing at least one cavity, wherein the at least one cavity is partitioned by the surface of a first membrane portion on at least a first side surface, and the shape (and / or position) of the first membrane portion is adjustable (for example, by forming the first membrane into a desired shape); b1) A step of filling at least one cavity for forming at least one optical component with a liquid material, wherein the liquid material comes into contact with a first surface of the first film portion; c1) A step of adjusting the shape of the first membrane portion; d1) A step of curing the liquid material filling the at least one cavity such that the cured liquid material forms a first interface of the at least one optical component, and the first interface has a shape defined by the shape of the first surface of the 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 the at least one optical component. However, the actual first optical surface of the at least one optical component can also be formed by a coating or layer placed on the first interface. In particular, the first film portion can remain on a rigid material. In this case, the first film portion preferably has the same refractive index as the hardened rigid material.

[0033] Preferably, according to one further embodiment, the rigid material is transparent when cured. Even more preferably, the liquid material is initially in a liquid state when it is filled into at least one cavity.

[0034] Furthermore, according to one embodiment of the present method, in step a), at least one cavity is formed by an opening formed in the mask, where the first membrane portion is connected to the mask and covers the opening such that it partitions at least one cavity on the first side surface.

[0035] According to one embodiment, the opening of the mask has one of the following contours: circular, non-circular, elliptical, or polygonal.

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

[0037] Furthermore, according to one embodiment, the mask forms the side wall of at least one cavity.

[0038] According to a further embodiment of the present method, the mask comprises, in step b1), at least one channel (or more channels) in which at least one cavity is filled with a liquid material.

[0039] Furthermore, according to one embodiment of the method of the present invention, the mask holds at least one optical component after the liquid material has cured.

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

[0041] Furthermore, in one embodiment, after the liquid material has cured in step d1), the first film portion is removed from the mask at least partially or completely, and the first interface coats and / or forms the first optical surface of at least one optical component. In another embodiment, after the liquid material has cured, the first film portion remains on the cured material (i.e., on the first interface) and coats and / or forms the first optical surface of at least one optical component.

[0042] In other words, the first interface can form the final first optical surface, or a layer (e.g., a coating) placed on the first interface can form the final first optical surface. In particular, the first optical surface can be formed by a first film portion or layer (e.g., a coating) placed on it.

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

[0044] Furthermore, in particular to provide the at least one channel (or more channels) for filling at least one cavity with the liquid material, the mask comprises a first portion and a second portion, the at least one channel being formed between the first portion and the second portion. In particular, the first portion and the second portion of the mask can each be formed as plates, and these plates are in direct contact with each other or are in close proximity to each other to form their respective channels. In particular, the first portion and the second portion have a main extension direction that extends essentially parallel to the first film. In particular, for the separation of at least one optical component in step d), the two components (e.g., plates) can be separated from each other.

[0045] Furthermore, according to a preferred embodiment of the method according to the present invention, the mask is flexible. The flexibility of the mask makes it possible to easily deform the first film portion to a desired shape, thereby adjusting the surface of the first film portion and the resulting first interface (particularly the first optical interface) of at least one optical component manufactured using the method according to the present invention.

[0046] According to a further embodiment of the present method, the opening of the mask is surrounded by a transparent circumferential portion of the mask, in particular, to define the lateral surface of at least one optical component (e.g., a lens) when the liquid material has cured (e.g., step d).

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

[0048] In particular, in one embodiment, the optical element has 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 hardens (e.g., step d1).

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

[0050] According to a further embodiment of the Method, including step e2) of the Method, in step a1) of the Method, at least one cavity is defined by a second surface facing the first surface by the surface of the second film portion, where the shape (and / or position) of the second film portion is adjustable (for example, by forming the second film portion into a desired shape). Thus, the second film portion makes it possible to adjust the shape of the second interface (e.g., optical surface) of at least one optical component.

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

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

[0053] Furthermore, according to the embodiment, step d1) further includes curing the liquid material filling 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 having a shape defined by the adjusted shape of the surface of the second film portion.

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

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

[0056] According to another embodiment of the present method, the carrier forms a mount for at least one optical component after the liquid material has cured in step d1).

[0057] According to one preferred embodiment, the carrier is a printed circuit board. This is advantageous because the optical component can be directly positioned relative to further components on the printed circuit board that operably interact with the optical component.

[0058] Preferably, according to further embodiments, the carrier comprises a first surface, particularly a first film portion, and at least one opening and at least one cavity, and in step b1), the liquid material is preferably also filled into the at least one opening in order to connect at least one optical component to the carrier in a shape-conforming manner as the liquid material is cured. In particular, step d1) further includes curing the liquid material filled into the at least one cavity and at least one opening of the carrier in order to connect at least one optical component to the carrier in a shape-conforming manner.

[0059] Advantageously, according to a further embodiment, at least one opening of the carrier is used as an aperture for at least one optical component.

[0060] In another embodiment, instead of an opening in the carrier, the carrier may be a transparent carrier. The transparent carrier may include glass or a polymer, and preferably the transparent carrier includes the same material as the rigid material. The carrier has a first side facing the liquid material that fills the cavity in step b1) of the method, and a second side facing the opposite side of the carrier from the first side. 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 separates the transparent carrier by at least one cavity into a first region beginning from a first side and extending in the opposite direction from the carrier, and a second region beginning from a second side and extending in the opposite direction from the carrier. Specifically, the first region is located between a first membrane portion and a first side of the carrier, and the second region is located between the second membrane portion and a second side of the carrier.

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

[0063] In particular, according to the above embodiment, step d1) further includes curing a liquid material filled in a first region of at least one cavity so that a rigid material is bonded to the first side surface 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 curing the liquid material on both sides of the carrier can be carried out in independent processing steps, i.e., 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 can be processed in further steps b2), c2), and d2), i.e., in corresponding embodiments, the method further steps: b2) A step of filling a second region of at least one cavity with a liquid material such that the liquid material is in contact with the second side surface of the carrier, in particular the surface of the second membrane portion; c2) A step of adjusting the shape of the second surface of the liquid material in the second region; d2) A step of hardening a material filled in a second region in at least one cavity 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 joined to the second side surface of the carrier; This includes, in particular, the second interface forms an optical surface of at least one optical component. The second interface may have 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 located on the side surface of the first film portion that faces away from the rigid material of at least one optical component.

[0066] According to another embodiment, the first film portion comprises a surface structure, particularly a nanostructure, disposed on the side surface of the first film portion facing the rigid material of at least one optical component. In particular, this surface structure allows the first optical surface to become an anti-reflective first optical surface when the first film portion is removed from the cured liquid material.

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

[0068] According to one preferred embodiment, the AR layer comprises nanostructures. Each nanostructure can be a moth-eye anti-reflective structure, i.e., an array comprising multiple protrusions, the size of which each protrusion is smaller than the wavelength of light incident on it. These protrusions form a region of stepped refractive index at the interface between the two media, essentially reducing the amount of light reflected by the interface.

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

[0070] Furthermore, according to one embodiment, the first film portion may be provided with a scratch-resistant layer on the side facing away from the rigid material of at least one optical component. In particular, the first film portion remains on the first interface and specifically forms the first optical surface.

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

[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 in a liquid state into at least one cavity (in particular into a first region and / or a second region of at least one cavity).

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

[0075] In particular, after filling the cavity with the liquid material, the liquid material may be degassed. The liquid material may be degassed by reducing the pressure of the liquid material, for example, by reducing the pressure of the adjacent fluid material. In particular, the cavity is configured to apply ultrasound to the liquid material for degassing. Gas separated from the liquid material during degassing can be captured in a dedicated area of ​​the cavity. In particular, gravity and / or centrifugal force can be used to move the gas into this dedicated area. The gas separated from the liquid material can be moved into the dedicated area by the continuous flow of the liquid material within the cavity. Alternatively, the gas separated from the liquid material during degassing may be removed from the cavity. For example, the gas separated from the liquid may be discharged from the cavity through a further open side.

[0076] With regard to the adjustment of the shape of each film portion used to define the shape of each interface / optical surface of at least one optical component, various techniques can be used according to the present invention. In particular, steps c1) and / or c2) of the method include at least one of the following: - Deforming the mask (in particular, by deforming the mask, the astigmatism and prism of at least one optical component can be adjusted); - Applying pressure to the mask at several points simultaneously; - Adjusting the pressure of the liquid material and / or the ambient pressure outside at least one cavity; - Adsorbing or pressing the first membrane portion onto the mold, and / or adsorbing or pressing the second membrane portion onto the mold; - Pressing a master against a first film portion and / or against a second film portion [the master can be formed from a glass member, in particular a flat master (e.g., a flat glass member) is pressed against the first film portion, tilting the first film portion so as to form at least one optical component in a prism]; - Changing the distance between the first and second parts of the mask; - Changing the distance between the first membrane portion and the second membrane portion; - Rotating the liquid material such that the shape of the first and / or second (4b) surface is at least partially defined by the centrifugal force applied to the liquid material.

[0077] In further embodiments, the shapes of the first and / or second surfaces are measured in steps c1), c2), d1) and / or d2) of the method. In particular, when adjusting the surface shape of the first film portion, the shape of the first film portion is measured (for example, in reflection mode or transmission mode). Accordingly, the shape of the second film portion can also be measured (for example, in reflection mode or transmission mode).

[0078] A measuring unit may be provided for measuring the shape of the first and / or second surface. In particular, the shape of the first / second surface is adjusted by closed-loop control. The measuring unit may include a Shack-Hartmann sensor. In particular, the Shack-Hartmann sensor may include a variable optical component such as a variable lens or variable prism for illumination or imaging.

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

[0080] In a more preferred embodiment of the method according to the present invention, the shapes of the first surface (4a) and / or the second surface (4b) are iteratively adjusted. In particular, the shapes of the first surface and the second surface are measured and adjusted simultaneously or alternately. Furthermore, in one embodiment, the shapes of the first and second film portions are iteratively adjusted, where the shapes of the first and second film portions are measured and adjusted simultaneously or alternately.

[0081] In particular, according to one embodiment, the first and / or second interface (e.g., optical surface) of at least one optical component can be measured before the liquid material hardens.

[0082] Furthermore, according to a preferred embodiment of the method according to the present invention, the liquid material is irradiated with UV light (for example, step d1) or d2)) in order to cure the liquid material.

[0083] In particular, in one embodiment, the mask may be positioned to block a portion of the UV light, thereby defining the contour of at least one optical component. Specifically, the mask can define the non-circular contour of at least one optical component. Furthermore, multiple optical components may be fabricated simultaneously within a cavity, where the mask can be positioned to shield the areas between adjacent optical components from UV radiation. Such a structure of the mask facilitates the separation of multiple optical components because the liquid material between adjacent optical components remains liquid. Therefore, after curing, the optical components (such as lenses) are not interconnected with rigid material. For example, excess liquid material can be rinsed off to separate the optical components.

[0084] Furthermore, according to one embodiment, UV light is emitted so as to be incident uniformly (particularly collimated) onto a liquid material filling at least one cavity.

[0085] In particular, in one embodiment, to avoid uneven hardening caused by curvature of the first surface, especially the first film portion, a transition liquid is placed on top of the first film portion, and this transition liquid has a refractive index equal to that of the liquid material, especially the refractive index of the rigid material of at least one optical component. This avoids refraction of UV light as it is transmitted from the transition liquid to the liquid material.

[0086] According to one embodiment of this method, a small area of ​​liquid material in at least one optical component is cured continuously.

[0087] According to one embodiment, the liquid material can be cured continuously from both opposing sides of at least one cavity.

[0088] In particular, according to one embodiment, the liquid material comprises first and second sub-regions, the first sub-region being cured first to become a fixpoint, the second sub-region being cured thereafter, where 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 multiple lenses, wherein multiple edges of the lens array (forming a first subregion) are cured first, and then multiple lenses of the lens array (forming a second subregion) are cured.

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

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

[0092] According to a further embodiment, the liquid material is cured by a light beam (particularly a laser beam) having a diameter smaller than the diameter of at least one optical component, where the light beam scans a first surface to cure the liquid material. Similarly, in one embodiment, such a light beam can scan a second surface.

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

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

[0095] Furthermore, according to one embodiment of this method, the mask is removed after the liquid material of at least one optical component has been cured.

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

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

[0098] In a further embodiment, after the liquid material of at least one optical component has cured, the second film portion is at least partially or completely removed, and the second interface is coated and / or formed on the second optical surface of at least one optical component. Alternatively, after the liquid material of at least one optical component has cured, the second film portion remains on the cured liquid material and is coated and / or formed on the second optical surface of at least one optical component.

[0099] In particular, in this context, partial removal of each film portion can mean that only the layer of each film (e.g., the support layer, see below) is removed, while another layer of each film portion (e.g., the film portion layer) remains on the first interface.

[0100] Furthermore, in one embodiment, an AR layer, such as a coating (see also above), disposed between the support layer of the first film portion and the rigid material may remain at the first interface. Similarly, an AR layer, such as a coating (see also above), disposed between the support layer of the second film portion and the rigid material may remain at the second interface of at least one optical component.

[0101] In a further embodiment, the method is for manufacturing multiple optical components.

[0102] Therefore, in step a1) of the method, a plurality of cavities are provided. Each of the plurality of cavities may be partitioned by at least one side surface of a first membrane portion (for example, a flexible one), where the shape of each first membrane portion is adjustable (for example, by forming each first membrane portion into a desired shape).

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

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

[0105] In step d1) of the method, the liquid material is hardened so that it becomes a rigid material and the first surface becomes a first interface (e.g., an optical surface), where the shape of the first interface is determined by the adjusted shape of the first surface.

[0106] In particular, all embodiments described herein may include forming multiple optical components instead of at least one optical component. The mask also comprises a corresponding number of openings, as well as a first film portion and, in particular, a second film portion.

[0107] In particular, according to one embodiment of the present method, each of the plurality of cavities is formed by an opening formed in the mask, and each first membrane portion is connected to the mask and covers each opening such that it partitions each cavity on at least one side.

[0108] If two or more cavities exist, each first membrane portion can be formed by a separate (e.g., flexible) first membrane. However, the first membrane portions can instead form integrated portions of a single (e.g., flexible) first membrane. The same applies to the second membrane portions; that is, each second membrane portion can be formed by a separate (e.g., flexible) second membrane, or instead form integrated portions of a single (e.g., flexible) second membrane.

[0109] According to one embodiment, with respect to step a1), each cavity is demarcated by a second membrane portion on a second surface opposite to the first surface, and the shape (and / or position) of each second membrane portion is adjustable (for example, by forming each second membrane portion into a desired shape).

[0110] In particular, in one embodiment, step b1) further includes filling each cavity with liquid material such that the liquid material also comes into contact with the surface of each second film portion.

[0111] Furthermore, in one embodiment, step c1) further includes adjusting the shape of each second film portion.

[0112] Furthermore, according to one embodiment, step d1) further includes curing the liquid material filling each cavity so that the liquid material forms a second interface (e.g., an optical surface), each of which the shape of the second interface is defined by the adjusted shape of the surface of each of the second film portions.

[0113] Furthermore, in the case of multiple cavities and / or multiple first film portions and especially second film portions, each film portion can be removed after the liquid material has hardened, or it can remain on its respective interface as described above, so that each optical surface can be formed with respect to the first / second film portion by either the interface (or a layer / coating placed thereon) or each film portion (or a layer / coating placed thereon) as described above.

[0114] According to one preferred embodiment, the optical components are connected to each other to form an array of optical components, in particular each of which is a lens (i.e., the array of optical components is a lens array).

[0115] In particular, any excess liquid material between adjacent optical components is removed after the liquid material has cured.

[0116] According to a further embodiment, in step f1) of the method, individual optical components (in particular lenses) are cut out from the array by at least one of the following means, in particular milling, laser cutting, stamping, cutting, and punching. Step f1) of the method is performed after step d1) of the method. In particular, step f1) of the method includes steps f2) and / or f3) of the method.

[0117] According to one embodiment, the method includes step e2) of the method and further steps b2), c2), and d2) of the method, thereby creating further interfaces and forming further optical surfaces of the optical component. In particular, steps b2), c2), and d2) of the method may be repeated multiple times to form multiple further interfaces, where each further interface may have a distinct shape. The rigid materials formed thereafter are adjacent to each other and have different refractive indices. As a result, these further interfaces each form a refractive surface with respect to the optical component.

[0118] In step b2) of the method, additional liquid material is filled into at least one cavity, where the additional liquid material is adjacent to the interface created in step d1) or d2) of the previous method. If steps b2), c2), and d2) of the method are repeated multiple times, the additional liquid material is adjacent to the interface created in the previous iteration.

[0119] In step c2) of the method, the shape of an additional surface is adjusted, and the additional surface (4c) is positioned on the side of an additional liquid material facing the interface (40a) created in step d1) or d2) of the preceding method.

[0120] In step d2) of the method, further liquid material is hardened to become further rigid material, and further surface (4c) is hardened to become further interface (40c), where the shape of the further interface (40c) is defined by the shape of the further surface (4c). Steps b2), c2), and d2) of the method are performed after step d1) of the method.

[0121] The rigid material and / or further rigid material(s) may form a refractive optical component that can be achromatic, apochromatic, or superachromatic. In particular, the rigid material and / or further rigid material(s) may have various Abbe numbers and various refractive indices. Specifically, the rigid material and / or further rigid material(s) may be firmly joined at the interface or further interface in a manner that conforms to the shape. Thus, the optical component comprises a rigid material and / or further rigid material formed in an integral manner.

[0122] Advantageously, the present invention can be used to create blanks for eyeglasses, augmented reality and virtual reality headsets, endoscopes, camera lenses and any spherical and aspherical lenses, prisms, and any other optical components.

[0123] Yet another aspect of the present invention relates to an optical device comprising at least one optical component (or more optical components) manufactured by the method according to the present invention.

[0124] Further aspects of the present invention relate to an optical device, the optical device being: - Rigid materials, - Components that are at least partially embedded in the rigid material, Equipped with, The optical device comprises at least one optical surface configured to influence the interaction of light with the components in a predetermined manner, wherein the at least one optical surface is formed of one of a rigid material, a layer disposed on the rigid material (e.g., an anti-reflective layer and / or a scratch-resistant layer), or a film portion disposed on the rigid material.

[0125] In particular, the film portion may comprise such a layer or any other coating.

[0126] According to a preferred embodiment of this optical device, the component is completely embedded in a rigid material such that the rigid material covers the component on all sides.

[0127] In a further embodiment, the embedded component is one of the following: an electronic component, an optical component, a diffraction grating, an optical aperture, a filter, an optoelectronic component, a gemstone, a sensor, or a light source.

[0128] According to yet another embodiment of the optical device, at least one optical surface is formed in the liquid state of a rigid material.

[0129] According to yet another aspect of the present invention, a device for manufacturing at least one optical component is disclosed, the device: - At least one cavity (2) for receiving a liquid curable material (4), - An actuator unit for defining the shape of the first surface (4a) of the liquid-curable material (4) within the cavity (2), and - A curing unit (102) for curing the liquid material (4) while the liquid material is in the at least one cavity (2), It is equipped with.

[0130] According to one embodiment of a device for manufacturing at least one optical component: - Mask with an opening, - A first membrane portion connected to the mask and covering the opening, such that the at least one cavity is partitioned by at least a first side, wherein the first membrane portion has a surface for defining the shape of a first interface (e.g., an optical surface) of at least one optical component to be manufactured, when the liquid material is filled into the at least one cavity and in contact with the surface of the first membrane portion, - An actuator unit configured to adjust the shape of a first film portion in order to adjust the shape of the interface of at least one optical component, and - A curing unit for curing the liquid material when the liquid material is filled into at least one cavity, It is equipped with.

[0131] According to one embodiment of the device, the curing unit may be a UV light source configured to emit UV light, a heater configured to heat the liquid material in the cavity, or a cooling unit configured to cool the liquid material.

[0132] According to a further embodiment of the device, the device may include a mount configured to hold at least one cavity portion that is limited on at least one side by a first membrane portion.

[0133] According to yet another embodiment of the device, the device comprises a filling unit configured to fill at least one cavity with the liquid material.

[0134] Further features and advantages of the present invention, similar to those of the embodiments of the present invention, will be described below with reference to the figures.

[0135] Figure 1 shows a general concept of the method according to the present invention. The method uses a cavity 2 partitioned on one side by a first film portion 3. The first film portion 3 has a surface 3a that will come into contact with the liquid material 4 that will be filled into the cavity 2. The material is in a liquid state, and the film 3 is adjusted to form, for example, a convex lens surface. The liquid material 4 that has been filled into the cavity 2 can be cured by either heat 8 or UV light 8, depending on the liquid material 4. The optical component 1 has an interface 1a in the form of an optical surface 1a having a shape corresponding to the shape of the surface 3a of the first film portion 3. In general, the actual optical surface can be formed by the interface 1a, but it can also be formed by a layer (e.g., a coating) placed on the interface 1a. In particular, the first film portion 3 can remain on the cured material 4 / interface 1a and then form the actual optical surface. The first film portion 3 may also be further processed to form an optical surface using the first film portion 3 as a base.

[0136] In particular, the curable liquid material is generally a UV-curable polymer that is transparent to visible light.

[0137] In particular, the cavity 2 can be formed by an opening 5a formed in a mask 5 that forms the side wall 5b of the cavity 2 and thereby defines the lateral contour of the optical component 1 to be manufactured. The opening 5a is preferably covered by a flexible first film portion 3, which partitions the cavity 2 and can hold the liquid / rigid material 4 within the cavity 2.

[0138] A force 10 can be applied to the flexible mask 5 to adjust the shape of surface 3a and its associated optical surface 1a, where the force extends particularly along the optical axis running perpendicular to the mask 5. Figure 2 shows an example where the optical surface 1a becomes convex by applying the force 10 to any side of the opening 5a of the mask 5. Different forces can be applied, for example, to form an optical component into a prism.

[0139] Figure 3 shows a modified example of the embodiments shown in Figures 1 and 2, in which the mask 5 is provided with at least one channel 7 for filling the cavity 2 of the mask with liquid material.

[0140] In particular, the mask 5 may comprise first and second portions 51 and 52 stacked on top of each other in the stacked configuration of portions 51 and 52 shown in Figure 3, and together forming at least one channel 7. However, the channel 7 can also be formed in other ways.

[0141] Here too, the cavity 2 can be formed by the opening 5a of the mask 5, which is here partitioned by two opposing sides by a flexible first membrane portion 3 and a flexible second membrane portion 6.

[0142] By using this configuration of the mask 5, it is possible to produce an optical component 1 having two opposing optical surfaces 1a and 1b, which can be shaped according to the shapes of the surfaces 3a and 6a of the respective film portions 3 and 6 that the liquid material 4 comes into contact with when it fills the cavity portion 2 through at least one channel 7.

[0143] Once surfaces 3a and 6a reach the desired shape, the liquid material inside the cavity 2 can be cured to form the optical component 1 (in this case, for example, a biconvex lens 1).

[0144] Figures 1-3 show only a single cavity 2. However, the method also includes embodiments in which multiple such cavities 2 are arranged side by side to form multiple optical components 1 in parallel. Ultimately, the optical components 1 can be separated from each other to form individual optical devices 1. Alternatively, the optical components 1 can be maintained in an interconnected configuration of optical devices in the form of an array of connected optical devices 1, such as a lens array.

[0145] Figure 4 shows an example of manufacturing such a lens array, which is composed of multiple optical components 1, by a two-stage process.

[0146] Here, the mask 5 has a plurality of openings 5a, each opening 5a bordering a flexible first membrane portion 3. The first membrane portion 3 may extend continuously between the mask 5 and the cavity 2. Alternatively, each opening 5a may be sealed by a separate first membrane portion 3.

[0147] In particular, the interconnected optical components 1 can be cured in two stages. In the first step, the cavity 2 is partitioned by a side mask 5 and film portion 3, as shown in the upper part of Figure 4, and by a carrier 9 positioned on the opposite side of the mask 5 and film portion 3. After the surface 3a is formed as desired, the interconnected cavity 2 is filled with liquid material 4. Next, after the first curing step to obtain the front half of the final array of optical components 1, this cured half is turned over and the carrier 9 is removed. In the second step, the cured half partitions the cavity 2 in place of the carrier. The cavity 2 partitioned by the cured half of the array of optical components 1 and the mask 5 with film portion 3 is then filled with liquid material 4, which bonds to the already cured half as the liquid material 4 cures. As a result, an array of optical components 1 in the form of biconvex lenses is obtained. However, arrays of other optical components 1 can also be formed in this way.

[0148] Figure 5 shows another modification of the method according to the present invention. Here, for example, is a blank optical element 11, which defines a cavity (or a plurality of cavities) 2 on the side facing the first film portion 3. This optical element 11 is bonded to the rigid material 4 during curing. In particular, the rigid material 4 and the optical element 11 may have the same refractive index. Furthermore, the optical element 11 may have a concave or convex surface 11a facing away from the rigid material 4.

[0149] In particular, after the liquid material 4 has hardened, the thickness of the rigid material 40 along the z-direction is smaller than the thickness of the optical element along the z-direction. For example, the optical element can be selected such that the deviation between the shape of the first surface 4a and 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, and this 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.

[0150] According to yet another embodiment shown in Figure 6, the mask 5 can be made of an opaque material. Thus, the mask 5 defines the contour of the portion of the liquid material that is cured by UV light 8 or heat 8, as shown in Figure 6.

[0151] Figure 7 shows the shaping of the surfaces 3a and 6a of further possible film portions 3 and 6 in order to form the final optical surfaces 1a and 1b of the optical component 1 manufactured by this method. In particular, the embodiment shown in Figure 7 uses a plurality of interconnected cavities 2 arranged side by side in the lateral direction, but uses the configuration shown in Figure 3.

[0152] To adjust the shapes of the first and second film portions 3 and 6, the pressure P1 of the liquid material 4 filling the cavity 2 is adjusted in relation to the ambient pressures P1 and P2 on either side of the mask 5, so that the shapes of the first and second film portions 3 and 6 become convex and concave optical components / lenses 1. However, other surface shapes 1a and 1b can also be easily generated depending on the pressures P1, P2 and P3.

[0153] Furthermore, Figure 8 shows one embodiment in which the shape of the first membrane portion 3 (or more) is adjusted by two molding fluids L1 and L2. The density ratio of the molding fluids L1 and L2 relative to each other, the density ratio relative to the liquid material 4, and the liquid levels L1 and L2 are selected to produce the desired shape of the first membrane portion, as shown in Figure 8.

[0154] Figure 9 shows yet another embodiment of the method according to the present invention, in which the carrier 9 is placed within the cavity 2. In particular, the carrier 9 may be a printed circuit board (PCB). The carrier 9 has an opening 9a in which two opposing film portions 3,6, namely a first film portion 3 and a second film portion 6, are aligned in a row, such that the opening 9a ultimately forms the aperture of the optical component 1 to be manufactured.

[0155] In particular, after adjusting the shape of the film portions 3 and 6 as desired, the liquid material 4 is placed in the opening 9a and above and below the carrier 9 (upper part of Figure 9). To cure the liquid material 4, it is preferable to expose the liquid material 4 to UV light 8 from both sides to avoid shadowing of the liquid material 4 by the carrier 9.

[0156] After the liquid material 4 has hardened (center of Figure 9), the mask 5 and the unhardened 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 in a shape-conforming manner (see lower part of Figure 9). In particular, the carrier 9 comprises a light-emitting element and / or a detection element. The light-emitting element and / or detection element may be embedded in the hardened material 4. In particular, the optical component 1 may be part of a gas sensor.

[0157] Furthermore, instead of providing an opening 9a, the carrier 9 may be continuous but transparent. Thus, the carrier 9 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 adjusting the shape of the first film portion 3, the liquid material 4 can be filled into the first region 2a of the cavity 2 between the first film portion 3 and the first side surface 91 of the carrier 9, and then cured to form the first optical surface 1a of the optical component 1. Alternatively, after adjusting the shape of the second film portion 6, the liquid material 4 can be filled into the second region 2b of the cavity 2 between the second film portion 6 and the second side surface 92 of the carrier 9, and then cured to form the second optical surface 1b of the optical component 1.

[0158] Using the method according to the present invention, prism-shaped optical components, or optical components comprising a prism, can also be manufactured, as shown in Figure 10.

[0159] Here, the first membrane portion 3 can also be made of a highly rigid material. The inclination of the first membrane portion 3 can be adjusted by applying force to the mask 5, in particular by adjusting the pressure of the liquid material relative to the environment. The liquid material can be cured by UV light 8 radiated through the first membrane portion 3. Within the framework of the present invention, the inclination position of the first membrane portion 3 is also considered to be part of the shape of the first membrane portion 3.

[0160] In particular, the method according to the present invention can be carried out by using a device 100 of the type shown in Figures 11 and 12 in an exemplary manner. This device 100 can be easily adapted to the individual embodiments already described above.

[0161] In particular, the device 100 includes a mask 5 (see also above), the mask 5 having at least one opening 5a having a first membrane portion 3 that covers the opening 5a. The mask 5 and the first membrane portion 3 partition the cavity 2 on at least one side. A filling unit is positioned to fill the cavity 2 with a liquid material 4.

[0162] In particular, the device comprises an actuator unit 101 which may include a plurality of actuators 103 that can be arranged circumferentially around the first film portion 3. In particular, the actuators 103 are configured to apply a force along the z-axis (e.g., the optical axis) onto the mask 5. This adjusts the position of the mask 5 along the z-axis. For example, the device 100 comprises at least four actuators 103, preferably at least eight actuators 103. Preferably, the actuators 103 are arranged equidistantly along the outer circumference of the first film portion 3 (or along the opening 5a). By adjusting the position of the mask 5 along the z-axis, the shape of the first film portion is adjusted, which then determines the final shape of the optical surface 1a of the optical component 1 manufactured by the device 100, due to the fact that the liquid material 4 comes into contact with the surface 3a of the first film portion 3 and thus takes the shape of the surface 3a of the first film portion 3.

[0163] Furthermore, preferably, the device includes a curing unit 102 (or a heater for heating the liquid material 4) such as UV light for generating UV light 8. The curing unit 102 is positioned to cure the liquid material 4 after the shape of the first film portion 3 has been adjusted by the actuator 103, for example as shown in Figure 12.

[0164] The method according to the present invention enables the cost-effective and rapid manufacture of customized optical surfaces with high optical quality.

[0165] Figure 13 shows a schematic cross-sectional view of an exemplary embodiment of a method for manufacturing at least one optical component, where the shape of the first surface 4a is defined by a piston 71. The piston 71 and the first film portion 3 partition the cavity 2 provided in step a1) of the method with two opposing sides. The mask 5 partitions the cavity 2 laterally.

[0166] In step b1) of the method, the liquid material 4 may be filled into the cavity 2 through the inlet 72. The inlet 72 is integrally formed within the piston.

[0167] The first surface 4a of the liquid material 4 is adjacent to the first membrane portion. In step c1) of the method, the shape of the first surface 4a of the liquid material 4 is adjusted by changing the pressure in the cavity 2. The pressure can be changed by moving the piston toward or toward the first membrane portion 3, and / or by filling the cavity with more or less liquid material 4 through the inlet 72.

[0168] In particular, the shape of the second surface 4b is determined by the shape of the piston 71. The piston 71 may include a rigid lens having a shape that forms a corresponding portion (half) of the desired shape of the second surface 4b. In particular, the rigid lens of the piston 71 can be manufactured according to steps a1), b1), c1), d1) and e1) of the method.

[0169] In step d1) of the method, the liquid material 4 is cured so that it becomes a rigid material 40 and the first surface 4a becomes a first interface 40a, where the shape of the first interface 40a is determined by the shape of the first surface 4a. The liquid material is cured by UV radiation 8 irradiated by the curing unit 102, and the UV radiation 8 passes through the transparent mask 5 and enters the cavity.

[0170] In a subsequent step of the method, at least one optical component may be formed by a molding process, wherein the first interface 40a provides at least one surface of a mold, and the shape of the optical surface of the optical component 1 is formed by the first interface 40a.

[0171] In place of step e1) of the method, in step e2 of the method, the optical component comprises a rigid material 40, and the first interface 40a is the optical surface of the optical component 1.

[0172] Figures 14a and 14b show schematic cross-sectional views of exemplary embodiments of a method for manufacturing at least one optical component, where a further interface 4c is fabricated.

[0173] As shown in Figure 14a, a cavity 2 is provided in step a1) of the method. The cavity 2 is partitioned on both opposing sides by the first membrane portion 3 and the 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 flat, transparent carrier. The mask 5 partitions the cavity 2 laterally. The mask 5 includes a bellows 53 that partitions the cavity laterally. The shape of the first membrane portion 3 may be adjusted by moving the mask 5 along the z direction. The mask 5, and in particular the bellows 53, provides a flexible and especially liquid-tight connection between the side wall 54 and the first membrane portion 3a.

[0174] The side walls 54 surround the carrier 9 circumferentially in the lateral direction (along the xy-plane). The carrier is movable in the Z direction. In particular, the carrier is attached to a positioning unit 93 positioned to move the carrier 9 along the z-axis. The positioning unit may be equipped with screw threads, which allows the position of the carrier 9 to be adjusted.

[0175] In step b1) of the method, the liquid material 4 is filled into the cavity 2. In step c1) of the method, the shape of the first surface 4a of the liquid material 4 is adjusted. In this particular embodiment, the first surface 4a is formed in a concave shape. Alternatively, the shape may be adjusted by changing the relative pressure between the cavity 2 and the region of the side surface facing the cavity with respect to the first membrane 3. Alternatively, the shape may be adjusted by moving the mask 5 along the z direction. Furthermore, the shape of the first membrane portion 3a may be adjusted by moving the carrier 9 along the z direction.

[0176] In step d1) of the method, the liquid material 4 is hardened so that it becomes a rigid material 40 and the first surface 4a becomes a first interface 40a, where the shape of the first interface 40a is determined by the shape of the first surface 4a.

[0177] After step d1) of the method, the position of the support 9 is adjusted along the z-direction, where the rigid material remains in contact with the support 9. Thus, an additional region 21 is created within the cavity 2, and this additional region 21 is partitioned on one side by the first interface 40a.

[0178] As shown in Figure 14b, in steps b2), c2), and d2) of the subsequent method, a further interface 40c is created. As shown in Figure 14b, in step b2) of the method, a further liquid material 41 is filled into at least one cavity, in particular a further region 21, and the further liquid 41 is adjacent to the interface 40a created in step d1) of the previous method. In particular, if multiple further interfaces 40c are created, the further liquid 41 may be adjacent to the further interface 40c created in step d2) of the previous method.

[0179] In step c2) of the method, the shape of a further surface 4c of the further liquid material is adjusted. The further surface 4c is located on the side surface of the further liquid material 41 facing the interfaces 40a, 40c created in step d1) or d2) of the method described above. The shape of the further surface can be adjusted by means similar to that of step c1) of the method.

[0180] In step d2) of the method, the further liquid material is hardened such that the further liquid material 41 becomes a further rigid material 410 and the further surface 4c becomes a further interface 40c, the shape of the further interface 40c is defined by the shape of the further surface 4c.

[0181] After performing at least one iteration of steps b2), c2), and d2) of the method, the optical component comprises a rigid material 40 and a further rigid material 410. The first interface 40a and the further interface 40c(or more) are optical surfaces of the optical component. In particular, the rigid material and the further rigid material have different refractive indices. The (further) rigid materials 40a, 40c, which are placed adjacent to each other, have different refractive indices, thereby the further interface 40c(or more) forms a refractive interface. In particular, the optical component is achromatic or apochromatic.

[0182] Figure 15 shows a schematic cross-sectional view of an exemplary embodiment of a method for manufacturing at least one optical component, in which the shape of the first surface 4a and / or the second surface 4b is measured by a measuring unit 120.

[0183] In step a1) of the method, a cavity 2 is provided, which is partitioned by a first membrane portion 3 and a second membrane portion 6 on opposite sides of the cavity. The mask 5 partitions the cavity 2 in the lateral direction (along the XY plane).

[0184] In step b1) of the method, the liquid material 4 is filled into the cavity 2 via the flow channel 7. The flow channel 7 connects the cavity 2 to the reservoir 55 containing the liquid material 4.

[0185] In step c1) of the method, 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 between the region adjacent to the first membrane portion 3 (pressure P2) and the second membrane portion 6 (pressure P3) and the cavity portion 2. The flow path 7 may remain open during step c1) of the method so that the liquid material 4 can flow between the cavity portion 2 and the reservoir 55. In particular, the reservoir 55 and the cavity portion 2 have the same pressure value P1. The reservoir 55 may remain open to maintain atmospheric pressure. The ratio of P1 to P2 may be defined independently of the ratio of P1 to P3. Since the cavity portion 2 maintains a constant pressure value P1, 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. Therefore, a change in the shape of the first or second surface causes the flow of liquid material through the flow path 7. Conveniently, adjusting the shape of the first surface does not affect the shape of the second surface, nor does it affect the second.

[0186] The measuring unit is configured to measure the shapes of the first surface 4a and the second surface 4b by a measuring beam 123 that penetrates the first surface 4a and the second surface 4b. Alternatively, the measuring unit may be configured to measure the shapes of the first / second surfaces (4a, 4b) by reflection from the first surface and / or the second surface. In particular, the measuring unit 120 includes a Shack-Hartmann sensor.

[0187] In step d1) of the method, the liquid material 4 is cured by UV radiation 8 such that the liquid material 4 becomes a rigid material 40, the first surface 4a becomes the first interface 40a, and the second surface 4b becomes the second interface 40b. The UV radiation is directed towards the cavity by a deflection mirror 81, which may 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 shows a schematic cross-sectional view of an exemplary embodiment of a method for manufacturing at least one optical component, where the shape of the second surface 4b is defined by an actuator unit 101. In particular, the actuator unit 101 is positioned to define the positions of discrete points of the second surface 4b along the z-axis. The actuator unit 101 comprises a plurality of actuators 103 positioned to press against the second film portion 6. In particular, the actuators include pins that contact the second film portion, and the position of the pins along the z-axis is adjustable. The actuator 103 for adjusting the position of the pin along the z-axis may be a piezo actuator, a voice coil actuator, a permanent magnet actuator, a stepping motor, or a hydraulic actuator.

[0188] The pressure P1 of the liquid material 4 remains constant during step c1) of the method. In particular, pressure P1 corresponds to atmospheric 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 adjusting the relative pressure between P1 and P2.

Claims

1. A method for manufacturing at least one optical component (1), comprising the following steps: a1) A step of providing at least one cavity (2), b1) A step of filling the at least one cavity (2) with liquid material (4), c1) A step of adjusting the shape of the first surface (4a) of the liquid material (4), d1) A step of hardening the liquid material (4) filled in the 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 any of the following: e1) A step of forming the at least one optical component by a molding process, wherein the first interface (40a) provides at least one surface of a mold, and the shape of the optical surface of the optical component (1) is formed by the first interface (40a), or e2) The optical component comprises the rigid material (40), and the first interface (40a) is the optical surface of the optical component (1). The method, including the method described above.

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

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 to 3, wherein the at least one cavity (2) is formed by an opening (5a) formed in the mask (5), and the first membrane portion (3) is connected to the mask (5) and covers the opening (5a) such that it partitions the at least one cavity (2) on the first side surface.

5. The method according to claim 4, wherein the mask (5) comprises at least one channel (7), and the at least one cavity (2) is filled with the liquid material (4) through the at least one channel (7).

6. The method according to claim 4 or 5, wherein after step d1) of the method, the mask (5) holds the rigid material (40).

7. The method according to any one of claims 1 to 6, comprising step e1) of the method, wherein the adhesion of the optical component to the first interface (40a) is reduced by the first interface (40a) or a coating applied on the film (3) disposed between the first interface (40a) and the optical component (1), or by a nanostructure formed by the first interface (40a).

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

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

10. The method according to claim 9, wherein the optical element (11) has a refractive index essentially equal to that 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 step d1) of the method, the optical element (11) is bonded to the rigid material (40).

12. The method according to any one of claims 9 to 11, wherein the optical element (11) has 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 includes step e2) of the method, wherein the at least one cavity (2) is partitioned by the surface (6a) of the second membrane portion (6) at a second surface facing the first surface, and 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 comes into contact with the surface (6a) of the second membrane portion (6), Step c1) further includes adjusting the shape of the second film portion (6), Step d1) further includes curing the liquid material (4) filling 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) having a shape defined by the shape of the surface (6a) of the second film portion (6). The method according to any one of claims 1 to 8.

14. The method includes step e2), Step a1) further includes providing a carrier (9), and in particular providing a carrier (9) for holding the at least one optical component (1), and Step d1) of the method 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 mount for the at least one optical component (1). The method according to any one of claims 1 to 13.

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) has at least one opening (9a), and in step d1) of the method, the liquid material (4) is also filled into the at least one opening (9a) of the carrier (9) in order to connect the at least one optical component (1) to the carrier (9) in a manner conforming to its shape.

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

18. The carrier (9) is a transparent carrier having a first side surface (91) facing the liquid material (4) that is filled into the cavity in step b1) of the method, and a second side surface (92) facing the opposite side of the carrier (9). The carrier (9) separates the at least one cavity (2) into a first region (2a) that starts from the first side surface (91) and extends in the opposite direction to the carrier (9), and a second region (2b) that starts from the second side surface (92) and extends in the opposite direction to the carrier (9). Here, step b1) further includes filling the at least one cavity (2) with the liquid material (4) such that the liquid material (4) is in contact with the first side surface (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 surface (91) of the carrier (9), The method according to claim 14 or 16.

19. The above method further involves the following steps: b2) A step of filling the second region (2b) of the at least one cavity (2) with the liquid material (4) such that the liquid material is in contact with the second side surface (92) of the carrier (9); c2) A step of adjusting the shape of the second surface (4b) of the liquid material (4) within the second region (2b); d2) A step of curing the liquid material (4) filled in the second region (2b) such that the liquid material (4) becomes a rigid material (40) 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 joined to the second side surface (92) of the carrier (9), the step Includes, The method of claim 18, wherein steps b2), c2), and d2) of the method are performed in the order described, after step d1) of the method.

20. Steps c1) and / or c2) of the method are: - Deforming the mask (5); - Applying pressure to the mask (5) at multiple locations on the mask (5) simultaneously; - Adjusting the pressure (P1) of the liquid material (4) and / or the ambient pressure (P2, P3) outside the at least one cavity (2); - To adsorb or press the first membrane portion (3) onto the mold, and / or to adsorb or press the second membrane portion (6) onto the mold; - Pressing the master against the first membrane portion (3) and / or pressing the master against the second membrane portion (6); - Changing the distance between the first part and the second part (51, 52) of the mask (5); - Changing the distance between the first membrane portion (3) and the second membrane portion (6); - Rotating the liquid material (4) such that the shape of the first surface (4a) and / or the second surface (4b) is at least partially defined by the centrifugal force applied to the liquid material (4); The method according to any one of claims 1 to 19, comprising at least one of the following.

21. The method according to any one of claims 1 to 20, wherein in steps c1), c2), d1) and / or d2), the shape of the first surface (4a) and / or the second surface (4b) is measured.

22. The method according to any one of claims 1 to 21, wherein the shape of the first surface (4a) and / or the second surface (4b) is repeatedly adjusted.

23. The method according to any one of claims 1 to 22, wherein in step d1) and / or step d2) of the method, the liquid material (4) is irradiated with UV light (8) for curing.

24. The method according to any one of claims 1 to 23, wherein in step d1) and / or step d2) of the method, a small area of ​​the liquid material (4) of the at least one optical component (1) is cured continuously.

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

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

27. In step a1) of the method, a plurality of cavities (2) are provided, In step b1) of the method, the plurality of cavities (2) are filled with the liquid material (4), and the liquid material (4) forms a first surface (4a) in each of the plurality of cavities (2); In step c1) of the method, the shape of the plurality of first surfaces (4a) is adjusted; and The method according to any one of claims 1 to 26, wherein in step d1), the liquid material (4) is hardened such that it becomes a rigid material (40) and the plurality of first surfaces (4a) become a plurality of first interfaces (40a), and the shape of the plurality of first interfaces (40a) is determined by the shape of the plurality of first surfaces (4a).

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

29. The method according to claim 29, wherein after the liquid material (4) has hardened, excess material between adjacent lenses is removed, in particular unhardened liquid material (4).

30. In step f1) of the method, the multiple lenses of the lens array are separated by at least one of the following means: milling, laser cutting, stamping, cutting, punching, Herein, step f1) of the method is the method according to claim 30, which is performed after step d1) of the method.

31. The method includes step e2), where, after step d1), In step b2) of the method, an additional liquid material is filled into the at least one cavity, where the additional liquid is adjacent to the interface created in step d1) or d2) of the preceding method. In step c2) of the method, the shape of the further surface (4c) is adjusted, where the further surface (4c) is positioned on the side of the further liquid material facing the interface (40a) created in step d1) or d2) of the preceding method, and The method according to any one of claims 1 to 30, wherein in step d2) the further liquid material is hardened such that the further liquid material becomes a further rigid material and the further surface (4c) becomes a further interface (40c), where the shape of the further interface (40c) is defined by the shape of the further surface (4c).

32. An optical device comprising at least one optical component (1) manufactured by the method described in any one of claims 1 to 31.

33. - Rigid material (40), - Components embedded at least partially in the rigid material (40), An optical device comprising, The optical device comprises at least one optical surface (1a, 1b) configured to influence the interaction of light with the components in a predetermined manner, wherein the at least one optical surface (1a, 1b) is formed by one of the following: the rigid material (40), the layer disposed on the rigid material (40), or the film portion disposed on the rigid material (40).

34. The optical device according to claim 33, wherein the aforementioned components are completely embedded in the rigid material (4).

35. The optical device according to claim 43 or 44, wherein the embedded component is one of an electronic component, an optical component, a diffraction grating, an optical aperture, a filter, a photoelectronic component, a gemstone, a sensor, or a light source.

36. The optical device according to any one of claims 43 to 45, wherein the at least one optical surface (1a, 1b) is formed in the rigid material (4) in a liquid state.

37. - At least one cavity (2) for receiving a liquid curable material (4), - An actuator unit for defining the shape of the first surface (4a) of the liquid curable material (4) within the cavity (2), and - A curing unit (102) for curing the liquid material (4) while the liquid material is in the at least one cavity (2), A device (100) for manufacturing at least one optical component (1) comprising the above.

38. - Mask (5) having an opening (5a), - A first membrane portion (3) connected to the mask (5) and covering the opening (5a) such that the at least one cavity (2) is partitioned by at least a first side surface, wherein the liquid material (4) is filled into the at least one cavity (2) and the first membrane portion (3) has a surface (3a) that defines the shape of the first interface (1a) of the at least one optical component (1) to be manufactured when it comes into contact with the surface (3a) of the first membrane portion (3), - An actuator unit (101) configured to adjust the shape of the first film portion (3) in order to adjust the shape of the interface (1a) of the at least one optical component (1), and - When the liquid material (4) is filled into the at least one cavity (2), a curing unit (102) for curing the liquid material (4) is provided. The device (100) according to claim 37, comprising:

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