Rapid prototyping of optical components, especially lenses, to produce customized optical surface shapes

Abstract

The present invention relates to a method for manufacturing at least one optical component (1), said method comprising the following steps: a) providing at least one cavity (2), said at least one cavity (2) being bounded on a first side by a surface (3a) of a first film portion (3), the shape of said first film portion (3) being adjustable; b) applying a material (4) to said first film portion (3) so as to contact the surface (3a) of said first film portion (3) to form said at least one optical component (1). The method includes the steps of: filling at least one cavity (2) with the material (4); c) adjusting the shape of the first film portion (3); and d) hardening the material (4) filled in the at least one cavity (2) so that the material (4) forms a first interface (e.g., a first optical surface) (1a) of the at least one optical component (1), the first interface (1a) having a shape defined by the shape of the surface (3a) of the first film portion (3).

Description

[Technical Field]

[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 using the method according to the invention. Furthermore, the present invention relates to an optical device with a customized optical surface and a device that can be used to implement the method according to the invention. [Background technology]

[0002] When it comes to manufacturing optical components, especially lenses, it is often challenging to ensure high optical quality while simultaneously molding each component in an efficient and fast enough manner. In particular, using traditional molds is relatively time-consuming due to the long lead time, which corresponds to the time from determining the part's shape to the finished part. Furthermore, established processes such as grinding / 3D milling are relatively expensive and time-consuming. Furthermore, while rapid prototyping based on 3D printing is fast and cost-effective, it often results in inferior quality, especially when applied to lenses. Summary of the Invention [Problem to be solved by the invention]

[0003] In view of the above, the problem that the present invention seeks to solve is to provide a method by which optical components such as lenses can be manufactured relatively quickly and cost-effectively, while at the same time ensuring sufficient optical quality. [Means for solving the problem]

[0004] 1. A method for manufacturing at least one optical component, comprising the steps of: a1) Providing at least one cavity (2) b1) filling said at least one cavity (2) with a liquid material (4); c1) adjusting the shape of the first surface (4a) of the liquid material (4); d1) hardening the liquid material (4) filled in the at least one cavity (2) so that the liquid material (4) becomes a rigid material (40) and the first surface (4a) becomes a first interface (40a), wherein the shape of the first interface (40a) is determined by the shape of the first surface (4a), and any of the following steps: e1) 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 an optical surface of the optical component (1); Includes. [Brief explanation of the drawings]

[0005] [Figure 1] FIG. 1 is a schematic diagram illustrating one embodiment of a method according to the present invention for manufacturing an optical component with a customized optical surface. [Figure 2] FIG. 2 shows an embodiment for adjusting the film portion for shaping the optical surface. [Figure 3] FIG. 3 shows a further embodiment of the method according to the invention using a mask with channels for applying the liquid material for forming the optical component(s). [Figure 4] FIG. 4 shows a further embodiment of a method according to the invention using a carrier to define a cavity used to form an optical component in a two-stage curing process. [Figure 5] FIG. 5 shows a further embodiment of the method according to the invention, using optical elements to which a rigid material is bonded upon hardening. [Figure 6] FIG. 6 shows a further embodiment of the method according to the invention, using optical elements to which a rigid material is bonded upon hardening. [Figure 7]FIG. 7 shows a further embodiment of a method according to the invention, in which the optical surface of an optical component is shaped by adjusting the pressure P1 of the liquid material relative to the ambient pressures P2, P3. [Figure 8] FIG. 8 shows a further embodiment of the method according to the invention, in which the optical surfaces of the optical component are shaped with the aid of shaping liquids L1, L2 influenced by gravity. [Figure 9] FIG. 9 shows a further embodiment of the method according to the invention using a carrier to which a rigid material is bonded upon hardening, where the carrier forms the aperture of the optical component. [Figure 10] FIG. 10 shows a further embodiment of a method according to the invention for manufacturing an optical component forming a prism. [Figure 11] FIG. 11 is a top view of a device for carrying out the method according to the invention. [Figure 12] FIG. 12 is a cross-sectional view of a device for carrying out the method according to the invention. [Figure 13] FIG. 13 shows in a schematic cross-sectional view 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] 14a and 14b show in schematic cross-sectional views an exemplary embodiment of a method for manufacturing at least one optical component, in which a further interface is created. [Figure 15] FIG. 15 shows in a schematic cross-sectional view an exemplary embodiment of a method for manufacturing at least one optical component, wherein the shape of the first and / or second surface is measured by a measurement unit. [Figure 16] FIG. 16 shows in a schematic cross-sectional view an exemplary embodiment of a method for manufacturing at least one optical component, where the shape of the second surface is defined by an actuation unit 101 . DETAILED DESCRIPTION OF THE INVENTION

[0006] In step a1) of the method, at least one cavity is provided. Here and hereinafter, a cavity is an enclosed space bounded by one or more solid structures. The solid structures may be elastically deformable, and the deformation of the solid structures may be 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 bound the liquid on all sides. In particular, the cavity is liquid-tight sealed. Alternatively, the cavity may be open to allow the flow of liquid through the cavity. For example, the cavity may include a valve configured to control the flow of liquid into and out of the cavity. The cavity may be configured to move the liquid in the cavity in a predetermined manner by pumping, convection, or tilting or rotating the cavity.

[0007] In step b1) of the method, a liquid material is filled into at least one cavity. Here and below, this liquid material has a maximum viscosity of 100,000 mPa·s, preferably a maximum viscosity of 1,000 mPa·s, and very preferably a maximum viscosity of 100 mPa·s. The cavity is configured to delimit the liquid material on at least one side. According to a first alternative, the cavity may be completely filled with the liquid material. According to a second alternative, the cavity is partially filled with the liquid material, and 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, and in step b1) of the method, the carrier is arranged in the cavity or the solid structure defining the cavity comprises said carrier. In particular, the liquid material is arranged on a surface of the carrier, the surface being curved, comprising nanostructures, comprising protrusions and / or comprising recesses. In particular, the carrier is a wafer, preferably comprising 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, which may in particular be at atmospheric pressure.

[0010] A reservoir containing the liquid material may be connected to the cavity. The cavity may have 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 may be continuously controlled. In particular, the liquid material may be pumped to circulate the liquid material within the cavity or to flow the liquid material through the cavity, and the movement of the liquid material may be more than convection.

[0011] In method step b2), which is performed after method step b1), the cavity can be closed. Thus, the opening through which the liquid material fills the cavity can be closed. In particular, the cavity can be closed by placing a flexible membrane on the first surface formed by the liquid material, with the flexible membrane adjacent to the liquid material. For example, the cavity can be closed by hardening a small area of ​​the liquid material, whereby the liquid material hardens in said small area.

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

[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 portion may have a non-uniform stiffness. In particular, the first / second membrane portion is shaped aspherically when the shape of the first / second membrane portion changes due to different pressures on opposite sides of the membrane. The stiffness of the first / second membrane portion may be anisotropic. In particular, the first / second membrane portion may have a non-uniform thickness, which results in a non-uniform stiffness of the first / second membrane portion.

[0014] In method step d1), the liquid material is hardened such that it becomes a rigid material and the first surface becomes a first interface, which has essentially the same shape as the first surface defined in method step c1). Here and below, a rigid material has a minimum viscosity of 100,000 mPa·s, preferably a minimum viscosity of 1,000,000 mPa·s, and very preferably a minimum viscosity of 10,000,000 mPa·s.

[0015] For example, the liquid material can be cured by UV radiation, which is applied to a small area of ​​the liquid material. The liquid material can be thermally cured, for example, by cooling the liquid material below its melting point, or by heating the liquid material above its curing temperature.

[0016] In particular, small areas are sequentially exposed to UV radiation.

[0017] In particular, UV radiation is applied in a manner that avoids the inclusion of the liquid material in the already cured rigid material during curing. For example, a small central area of ​​the liquid material is exposed first, followed by successive small areas around the central area. This advantageously reduces mechanical stress, cracks, and bubbles in the rigid material. For example, UV radiation is applied to a small central area, and the subsequently exposed small areas are arranged radially around the central area. For example, UV radiation is applied in spots, with the diameter of the spots successively increasing. The shape, position, and size of the spots can be controlled by variable optical components such as a tunable lens, a deformable mirror, or a variable prism.

[0018] The liquid material may be cured in a layered manner, in which layers of the liquid material are cured sequentially, in particular having a main direction of extension that is perpendicular to the optical axis of the optical component, in particular the layer comprising the first surface and / or the second surface being the last layer to be cured.

[0019] In particular, the cavity comprises a compensation area or a compensation area is adjacent to the cavity. This compensation area is in liquid connection with the portion of the liquid material that is hardened during step d1) of the method. This compensation area has a variable volume, so that a change in volume of the liquid material in the cavity upon hardening is compensated by a change in volume of the compensation area. In particular, the compensation area may be designed to be open to the ambient environment, so that a change in volume in the compensation area is compensated by ambient air flowing through the compensation area.

[0020] According to one embodiment, the shape of the first surface is altered while the liquid material is hardening. For example, a first small area of ​​the liquid material hardens to a rigid material, while other small areas of the liquid material within the cavity are not hardened. Before hardening the additional small areas of the liquid material, the position of the rigid material within the cavity is manipulated to alter the shape of the first surface. For example, after the first small area is exposed to UV radiation, a pin pushes the rigid material to alter its position, thereby altering the shape of the first surface.

[0021] In particular, the temperature of the solid structure enclosing the cavity and / or of the fluid material within the cavity is controlled. In particular, controlling the temperature of the liquid material within the cavity makes it possible to locally initiate, delay or accelerate the hardening of the liquid material. In particular, the temperature distribution within the liquid material is monitored during hardening of the liquid material in step d1) of the method.

[0022] According to a first alternative in step e1) of the method, 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, and 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 provides a counterpart (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, while its optical properties can be neglected. Step e1) of the method therefore means that there are fewer constraints on the material selection of the rigid material.

[0024] In step e2) of the method, according to a second alternative, the optical component comprises a rigid material. In particular, the optical component consists of a rigid material. The first interface comprises an optical surface of the optical component. The optical component may be a refractive optical component, which is configured to interact with light by providing the optical surface with a specialized shape and a specialized change in refractive index. In particular, the rigid material is essentially transparent to said 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, a metallization may be applied to the first interface to provide the reflectivity of the optical surface. The metallization and shape of the first interface may define the optical properties of the optical surface. In particular, the rigid material may be non-transparent to the electromagnetic waves expected to interact with the optical component.

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

[0026] In particular, the hardening of the liquid material may be controlled such that after method step d1), a layer of liquid material is adjacent to the rigid material. In particular, such a layer of liquid material may be disposed between the solid structure defining the cavity and the rigid material, facilitating the release of the rigid material from the cavity. In particular, after hardening in method step d1), 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 or sacrificial layer to facilitate release of the rigid material. If the cavity is bounded 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 method step d1), the rigid material is post-treated in method step f3), for example by: - Exposing rigid materials to UV radiation; - Tempering rigid materials; - coating rigid materials with anti-scratch coatings, optical filter coatings, anti-reflective coatings or reflective coatings; - Exposing rigid materials to vacuum; It includes at least one of the following:

[0029] In particular, the post-processing may include processing an edge region of the rigid material. The edge region is the portion of the rigid material that defines the outer contour of the rigid material, as seen in a top view of the first interface. Processing the edge region may include additive processing, such as blackening or coating the edge region. Processing the edge region may include conversion processing, such as oxidizing or plasma treating the edge region. Processing the edge region may include subtractive processing, such as removing a portion of the rigid material by etching, milling, punching, or cutting.

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

[0031] According to one embodiment, a method for manufacturing at least one optical component comprises the following steps: a1) providing at least one cavity, the at least one cavity being bounded on at least a first side by a surface of a first membrane portion, the shape (and / or position) of the first membrane portion being adjustable (e.g., by forming the first membrane into a desired shape); b1) filling the at least one cavity for forming at least one optical component with a liquid material, wherein the liquid material contacts a first surface of the first film portion; c1) adjusting the shape of the first film portion; d1) hardening the liquid material filled in the at least one cavity such that the hardened liquid material forms a first interface of the at least one optical component, the first interface having a shape defined by the shape of a first surface of the first film portion.

[0032] According to a preferred embodiment, the at least one optical component is a lens, and the optical surface is a 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 disposed on the first interface. In particular, the first film portion can remain on the rigid material. In this case, the first film portion preferably has the same refractive index as the hardened rigid material.

[0033] Preferably, according to a further embodiment, the rigid material is transparent when hardened.Furthermore, preferably, the liquid material is initially in a liquid state when it fills the at least one cavity.

[0034] Furthermore, according to one embodiment of the method, in step a), the at least one cavity is formed by an opening formed in the mask, wherein the first membrane portion is connected to the mask and covers the opening so as to define the at least one cavity on the first side.

[0035] According to one embodiment, the openings of the mask have one of a circular contour, a non-circular contour, an elliptical contour, or a polygonal contour.

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

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

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

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

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

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

[0042] That is, the first interface may form the final first optical surface, or a layer (e.g., coating) disposed on the first interface may form the final first optical surface. In particular, the first optical surface may be formed by a first film portion or layer (e.g., coating) disposed thereon.

[0043] In particular, partial removal of the first membrane portion may mean that only a layer of the first membrane portion (e.g., a carrier layer, see e.g., below) is removed, and 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 for providing the at least one flow path (or a plurality of flow paths) for filling the at least one cavity with the liquid material, the mask comprises a first part and a second part, and the at least one flow path is formed between the first part and the second part. In particular, the first part and the second part of the mask can each be formed as a plate, which is in direct contact with each other or is adjacent to each other to form the respective flow paths. In particular, the first part and the second part have a main extension direction extending essentially parallel to the first film. In particular, for the separation of the 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 invention, the mask is flexible, which allows it to be easily deformed to give the first film portion a desired shape and to adjust said surface of the first film portion and therefore the first interface (in particular the first optical interface) of at least one optical component manufactured using the method according to the invention.

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

[0047] According to one embodiment, the method comprises method step e2), in which the optical element is provided in step a) on a side of the mask facing away from the first surface, in particular the optical element is provided in step a) on a side of the mask facing away from the first film portion, in particular 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 the refractive index 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 the at least one cavity.

[0050] According to a further embodiment of the method comprising method step e2), in method step a1), at least one cavity is defined on a second side opposite to the first side by a surface of a second membrane portion, wherein the shape (and / or position) of the second membrane portion is adjustable (e.g., by forming the second membrane portion into a desired shape), thus allowing the shape of a second interface (e.g., optical surface) of at least one optical component to be adjusted.

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

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

[0053] Furthermore, according to the embodiment, step d1) further includes hardening the liquid material filled in the at least one cavity portion so that the liquid material forms a second interface (e.g., an optical surface) of the 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 method comprising method step e2), step a1) further comprises providing a carrier, which may be part of a solid structure enclosing the cavity.

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

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

[0057] According to one preferred embodiment, the carrier is a printed circuit board, which is advantageous since the optical component can be directly aligned with further components on the printed circuit board that operatively interact with the optical component.

[0058] Preferably, according to a further embodiment, the carrier comprises at least one opening and at least one cavity which may be aligned with the first surface, in particular the first membrane portion, and in step b1) the liquid material is also filled into said at least one opening in order to connect the at least one optical component to the carrier in a form-fitting manner when the liquid material is hardened. In particular, step d1) further comprises hardening the liquid material filled into the at least one cavity and into the at least one opening of the carrier in order to connect the at least one optical component to the carrier in a form-fitting manner.

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

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

[0061] In particular, the transparent carrier is continuous and separates at least one cavity into a first region starting from a first side and extending away from the carrier, and a second region starting from a second side and extending away from the carrier, in particular the first region being arranged between the first membrane portion and the first side of the carrier, and the second region being arranged between said second membrane portion and the second side of the carrier.

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

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

[0064] In particular, applying the liquid material to both sides of the carrier and adjusting the shape of the first and second surfaces, in particular adjusting the first and second membrane portions, and hardening the liquid material on both sides of the carrier can be performed in independent processing steps, i.e. in steps b1), c1) and d1) the liquid material on the first side of the carrier is treated, while the liquid material on the second side of the carrier can be treated in further steps b2), c2) and d2), i.e. in a corresponding embodiment the method comprises the further steps: b2) filling a second region of the at least one cavity with a liquid material so that the liquid material contacts a second side of the carrier, in particular a surface of the second membrane portion; c2) adjusting the shape of the second surface of the liquid material in the second region; d2) hardening the material filled in the second region in the 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 bonded to the second side of the carrier; In particular, the second interface forms an optical surface of the at least one optical component. The second interface can have a shape defined by a tailored shape of the surface of the second film portion.

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

[0066] According to another embodiment, the first film portion comprises a surface structure, in particular a nanostructure, arranged on a side of the first film portion facing the rigid material of at least one optical component, which surface structure in particular enables the first optical surface to become an anti-reflective first optical surface when the first film portion is removed from the hardened liquid material.

[0067] According to another embodiment, the first film portion comprises an anti-reflection layer (AR layer) arranged on one side of the carrier layer of the first film portion facing said liquid / rigid material of the at least one optical component, the AR layer having a refractive index between the refractive index of the rigid material and the refractive index of air, and after hardening of the liquid material, the carrier layer of the first film portion is removed and the AR layer remains on the hardened material, in particular on the at least one optical component.

[0068] According to a preferred embodiment, the AR layer comprises nanostructures. Each nanostructure can be a moth-eye anti-reflection structure, i.e., an array of protrusions, each of which has a dimension smaller than the wavelength of light incident thereon. These protrusions create a graded refractive index region at the interface between the two media, essentially reducing the amount of light reflected by the interface.

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

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

[0071] Furthermore, according to another embodiment, the first film portion may comprise a scratch-resistant layer arranged on one side of the carrier layer of the first film portion facing the hardened material, wherein, in particular, after hardening of the liquid material, the carrier layer of the first film portion is removed and the scratch-resistant layer remains at the first interface, in particular forming the first optical surface.

[0072] The second film portion can be used in a similar manner to create 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 the at least one cavity (in particular into the first region and / or the second region of the at least one cavity).

[0074] Furthermore, according to one preferred embodiment, step b) of the method further comprises degassing the liquid material after filling at least one cavity with the liquid material (in particular after filling the first and / or second region of the 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 an 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 trapped in a dedicated area of ​​the cavity. In particular, gravity and / or centrifugal force can be used to move the gas to this dedicated area. Gas separated from the liquid material can be moved to the dedicated area by the continuous flow of liquid material within the cavity. Alternatively, gas separated from the liquid material during degassing can be removed from the cavity. For example, gas separating from the liquid can be discharged from the cavity at a further open side.

[0076] Regarding the adjustment of the shape of the respective membrane portions used to define the shape of the respective interfaces / optical surfaces of the at least one optical component, various techniques can be used according to the invention. In particular, steps c1) and / or c2) of the method comprise at least one of the following: - deforming the mask (in particular, by deforming the mask it is possible to adjust the astigmatism and prism of at least one optical component); - Applying pressure to the mask at several points simultaneously; - adjusting the pressure of the liquid material and / or the ambient pressure outside the at least one cavity; - sucking or pressing the first membrane portion onto the mold and / or sucking or pressing the second membrane portion onto the mold; - pressing the master against the first film portion and / or pressing the master against the second film portion (the master can be formed by a glass element, in particular a flat master (e.g. a flat glass element) is pressed against the first film portion, tilting the first film portion so as to form at least one optical element into a prism); - Varying the distance between the first and second parts of the mask; - changing the distance between the first membrane portion and the second membrane portion; - Spinning the liquid material such that the shape of the first and / or second (4b) surfaces is at least partly determined by centrifugal force applied to the liquid material.

[0077] According to a further embodiment, in steps c1), c2), d1) and / or d2) of the method, the shape of the first and / or second surface is measured. In particular, when adjusting the shape of the surface of the first film part, the shape of the first film part is measured (e.g., in reflection or transmission mode). Correspondingly, the shape of the second film part can also be measured (e.g., in reflection or transmission mode).

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

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

[0080] According to a still further preferred embodiment of the method according to the invention, the shape of the first surface (4a) and / or the second surface (4b) is iteratively adjusted. In particular, the shapes of the first and second surfaces are measured and adjusted simultaneously or alternately. Furthermore, according to one embodiment, the shapes of the first and second membrane portions are iteratively adjusted, wherein the shapes of the first and second membrane portions are measured and adjusted simultaneously or alternately.

[0081] In particular, according to one embodiment, the first and / or second interface (eg, optical surface) of at least one optical component may be measured prior to curing of the liquid material.

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

[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. In particular, the mask may define a non-circular contour of at least one optical component. Furthermore, multiple optical components may be fabricated simultaneously within the cavity, where the mask may be positioned to shield areas between adjacent optical components from UV radiation. This mask configuration facilitates separation of multiple optical components because the liquid material between adjacent optical components remains liquid. Therefore, after curing, the optical components (e.g., lenses) are not interconnected by a rigid material. For example, excess liquid material can be rinsed away to separate the optical components.

[0084] Furthermore, according to one embodiment, the UV light is emitted so as to be uniformly (in particular collimated) incident on the liquid material filled in the at least one cavity.

[0085] In particular, in one embodiment, to avoid uneven curing caused by curvature of the first surface, in particular the first film portion, a transition liquid is placed on top of the first film portion, which transition liquid has a refractive index equal to the refractive index of the liquid material, in particular the refractive index of the rigid material of the at least one optical component, thereby avoiding refraction of UV light when transmitted from the transition liquid to the liquid material.

[0086] According to one embodiment of the method, small areas of the liquid material of at least one optical component are successively hardened.

[0087] According to one embodiment, the liquid material is capable of solidifying continuously from opposite sides of the at least one cavity.

[0088] In particular, according to one embodiment, the liquid material comprises first and second subregions, the first subregion being hardened first to become a fixpoint, and the second subregion being hardened thereafter, where the second subregion is adjacent to the first subregion.

[0089] For example, in one embodiment, at least one optical component is a lens array comprising a plurality of lenses, and a plurality of edges of the lens array (forming a first subregion) are cured first, followed by a plurality of lenses of the lens array (forming a second subregion).

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

[0091] Furthermore, according to one embodiment, the shape of the first surface, in particular the first film portion, and / or the second surface, in particular the second film portion, may be changed during the curing process, in which different small areas of the liquid material of the at least one optical component are cured successively.

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

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

[0094] According to another embodiment, the liquid material of at least one optical component is heated in order to harden the liquid material (eg in step d1) or d2)).

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

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

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

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

[0099] In particular, in this context, partial removal of the respective membrane portion can mean that only a layer of the respective membrane (e.g., a carrier layer, see below) is removed, and another layer of the respective membrane portion (e.g., a layer of the membrane portion) remains on the first interface.

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

[0101] According to a further embodiment, the method is for manufacturing a plurality of optical components.

[0102] To this end, in step a1) of the method, a plurality of cavities are provided, each of which may be bounded on at least one side by a surface of a (e.g., flexible) first membrane portion, wherein the shape of each first membrane portion is adjustable (e.g., by forming each first membrane portion into a desired shape).

[0103] In step b1) of the method, each cavity of the plurality of cavities is filled with a liquid material, which forms a respective first surface for each of the plurality of cavities, in particular in each cavity an optical component is formed, e.g., the liquid material contacts a surface of a respective first membrane portion.

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

[0105] In step d1) of the method, the liquid material is hardened such that the liquid material becomes a rigid material and the first surface becomes a first interface (e.g., an optical surface), the shape of the first interface being respectively defined 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, and the mask also comprises a corresponding number of openings, as well as first and, in particular, second membrane portions.

[0107] In particular, according to one embodiment of the method, each cavity of the plurality of cavities is formed by an opening formed in a mask, and each first membrane portion is connected to the mask so as to define a respective cavity on at least one side and covers the respective opening.

[0108] If two or more cavities are present, each first membrane portion can be formed by a separate (e.g., flexible) first membrane. However, the first membrane portions can instead form an integral part of a single (e.g., flexible) first membrane. The same is true for the second membrane portions, i.e., the second membrane portions can each be formed by a separate (e.g., flexible) second membrane, or can instead form an integral part of a single (e.g., flexible) second membrane.

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

[0110] In particular, in one embodiment, step b1) further comprises filling each cavity with a liquid material such that the liquid material also contacts the surface of each second membrane portion.

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

[0112] Furthermore, according to one embodiment, step d1) further comprises hardening the liquid material filled in each cavity portion so that the liquid material forms a second interface (e.g., an optical surface), each second interface having a shape defined by the adjusted shape of the surface of each second film portion.

[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 can remain on its respective interface as described above, so that each optical surface can be formed by either the interface (or a layer / coating disposed thereon) or each film portion (or a layer / coating disposed thereon) as described above for the first / second film portions.

[0114] According to a preferred embodiment, the optical components are connected to one another to form an array of optical components, in particular each of the optical components being a lens (ie the array of optical components is a lens array).

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

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

[0117] According to one embodiment, the method includes method step e2) and further method steps b2), c2), and d2), in which further interfaces are created, thereby forming further optical surfaces of the optical component. In particular, method steps b2), c2), and d2) may be repeated multiple times to form multiple further interfaces, where each further interface may have a distinct shape. The subsequently formed rigid materials are adjacent to each other and have different refractive indices. These further interfaces thereby form respective refractive surfaces for the optical component.

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

[0119] In method step c2) the shape of the further surface is adjusted and the further surface (4c) is placed on the side of the further liquid material opposite the interface (40a) created in the previous method step d1) or d2).

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

[0121] The rigid material and the further rigid material(s) may form a refractive optical component, which may be achromatic, apochromatic, or superachromatic. In particular, the rigid material and the further rigid material have different Abbe numbers and different refractive indices. In particular, the rigid material and the further rigid material are firmly joined in a form-fitting manner at an interface or further interface. In this way, the optical component comprises the rigid material and the further rigid material that are formed in an integral manner.

[0122] Advantageously, the present invention can be used to create blanks for eyeglasses, augmented 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 invention relates to an optical device comprising at least one optical component (or a plurality of optical components) manufactured by a method according to the invention.

[0124] A further aspect of the invention relates to an optical device, said optical device comprising: - rigid materials, - a component at least partially embedded in said rigid material; Equipped with The optical device comprises at least one optical surface configured to affect the interaction of light with the component in a predefined manner, the at least one optical surface being formed by one of a rigid material, a layer disposed on the rigid material (e.g., an anti-reflective layer and / or an anti-scratch layer), and a film portion disposed on the rigid material.

[0125] In particular, the membrane portion may be provided with such a layer or any other coating.

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

[0127] According to a further embodiment, the embedded component is one of an electronic component, an optical component, a diffraction grating, an optical aperture, a filter, an optoelectronic component, a piece of jewelry, 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 the 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 comprising: - at least one cavity (2) for receiving a liquid hardenable material (4), - an actuator unit for defining the shape of a first surface (4a) of the liquid hardenable material (4) in said cavity (2), and a hardening unit (102) for hardening said liquid material (4) while said liquid material is in said at least one cavity (2); Equipped with.

[0130] According to one embodiment of the device for manufacturing at least one optical component: - a mask with an opening; a first film portion connected to the mask and covering the opening so as to define the at least one cavity on at least a first side, the first film portion having a surface for defining a shape of a first interface (e.g., optical surface) of at least one optical component to be manufactured when the liquid material is filled into the at least one cavity and contacts the surface of the first film portion; - an actuator unit configured to adjust the shape of the first membrane portion in order to adjust the shape of an interface of the at least one optical component; and - a hardening unit for hardening the liquid material when said liquid material has been filled into said at least one cavity; Equipped with.

[0131] According to one embodiment of the device, the curing unit may be a UV light source configured to emit UV light, or 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 comprise a mount configured to hold at least one cavity bounded on at least one side by the 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 said liquid material.

[0134] Further features and advantages of the invention as well as embodiments of the invention are described below with reference to the drawings.

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

[0136] In particular, the curable liquid material may generally be a UV curable polymer that is preferably 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 sidewalls 5b of the cavity 2 and thereby defines the lateral contour of the optical component 1 to be manufactured. The opening 5a is covered by a first membrane portion 3, which is preferably flexible, that defines the cavity 2 and allows the liquid / rigid material 4 to be retained within the cavity 2.

[0138] To adjust the shape of surface 3a and the associated optical surface 1a, a force 10 can be applied to flexible mask 5, said force extending specifically along an optical axis running perpendicular to mask 5. Figure 2 shows an example where application of force 10 to either side of opening 5a in mask 5 causes optical surface 1a to assume a convex shape. The force can also be different, for example to form the optical component into a prism.

[0139] Figure 3 shows a modification of the embodiment shown in Figures 1 and 2, in which the mask 5 comprises at least one channel 7 for filling the mask cavity 2 with a liquid material.

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

[0141] Here again, the cavity 2 can be formed by an opening 5a in the mask 5, which opening 5a is here bounded on two opposing sides by a flexible first membrane portion 3 and a flexible second membrane portion 6.

[0142] By using such a configuration of the mask 5, an optical component 1 can be produced having two opposing optical surfaces 1a, 1b that can be shaped according to the shape of the surfaces 3a, 6a of the respective membrane portions 3, 6 that the liquid material 4 comes into contact with when it is filled into the cavity 2 through at least one flow path 7.

[0143] Once the surfaces 3a, 6a have the desired shape, the liquid material in the cavity 2 can be hardened to form the optical component 1 (here, for example, a biconvex lens 1).

[0144] 1-3, only a single cavity 2 is shown. However, the method also includes embodiments using multiple such cavities 2 arranged side by side so that multiple optical components 1 can be formed in parallel. Ultimately, the optical components 1 can be separated from one another 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] The manufacture of such a lens array consisting of a number of optical components 1 in a two-stage process is shown by way of example in FIG.

[0146] Here, the mask 5 has a plurality of openings 5a, each bordered by 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 a first step, the cavity 2 is defined by the side mask 5 and membrane portion 3, as well as by the carrier 9 arranged on the opposite side of the mask 5 and membrane portion 3, as shown in the upper part of FIG. 4. After shaping the surface 3a as desired, the interconnected cavity 2 is filled with a liquid material 4. Then, after the first curing step, which obtains the front half of the final array of optical components 1, this hardened half is turned over and the carrier 9 is removed. In a second step, the hardened half defines the cavity 2 instead of the carrier. The cavity 2 defined by the hardened half of the array of optical components 1 and the mask 5 with the membrane portion 3 is then filled with a liquid material 4, which joins with the already hardened half upon hardening of the liquid material 4. This results in an array of optical components 1 in the form of a biconvex lens, here. However, arrays of other optical components 1 can also be formed in this way.

[0148] 5 shows another variant of the method according to the invention. Here, for example, a blank optical element 11 is provided, which defines a cavity (or 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 hardening of the liquid material 4, the thickness of the rigid material 40 along the z-direction is smaller than the thickness of the optical element 11 along the z-direction. For example, the optical element 11 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, 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 and thus defines the outline of the portion of the liquid material that will be hardened by UV light 8 or heat 8, as shown in Figure 6.

[0151] 7 shows a further possible shaping of the surfaces 3a, 6a of the membrane portions 3, 6 to form the final optical surfaces 1a, 1b of the optical component 1 produced by this method. In particular, the embodiment shown in FIG. 7 uses multiple interconnected cavities 2 arranged side by side in the lateral direction, but using the configuration shown in FIG.

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

[0153] 8 further illustrates an embodiment in which the shape of the first membrane portion(s) 3 is adjusted by two forming liquids L1, L2. The density ratio of the forming liquids L1, L2 to each other and to the liquid material 4, as well as the liquid levels L1, L2, are selected to result in the desired shape of the first membrane portion, as shown in FIG.

[0154] 9 shows yet another embodiment of the method according to the invention, in which a carrier 9 is placed in the cavity 2. In particular, the carrier 9 may be a printed circuit board (PCB). The carrier 9 comprises an opening 9a in which two opposing film parts 3, 6, i.e. a first film part 3 and a second film part 6, are aligned, so that the opening 9a ultimately forms the aperture of the optical component 1 to be manufactured.

[0155] In particular, after the desired shapes of the membrane portions 3, 6 have been adjusted, the liquid material 4 is placed in the opening 9a as well as above and below the carrier 9 (top row of FIG. 9). For hardening of the liquid material 4, it is preferable to expose the liquid material 4 to UV light 8 from both sides to avoid the liquid material 4 being shadowed by the carrier 9.

[0156] After the liquid material 4 has hardened (center of Fig. 9), the mask 5 and the unhardened liquid material 4 are removed. In particular, the membrane parts 3, 6 are removed. Since the openings 9a are filled with material 4, the optical component 1 can be connected to the carrier in a form-fitting manner (see bottom part of Fig. 9). In particular, the carrier 9 comprises a light emitting and / or detecting element. The light emitting and / or detecting element may be embedded by 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 first region 2a of the cavity 2 between the first film portion 3 and the first side 91 of the carrier 9 can be filled with a liquid material 4, which can then be hardened to form the first optical surface 1a of the optical component 1. In another process, after adjusting the shape of the second film portion 6, the second region 2b of the cavity 2 between the second film portion 6 and the second side 92 of the carrier 9 can be filled with a liquid material 4, which can then be hardened to form the second optical surface 1b of the optical component 1.

[0158] The method according to the invention can also be used to create optical components in the form of prisms or comprising prisms, as shown in FIG.

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

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

[0161] In particular, the device 100 comprises a mask 5 (see also above) comprising at least one opening 5a with a first membrane portion 3 covering the opening 5a. The mask 5 and the first membrane portion 3 define on at least one side a cavity 2. A filling unit is arranged to fill the cavity 2 with a liquid material 4.

[0162] In particular, the device comprises an actuator unit 101 which may comprise a plurality of actuators 103 which may be arranged in a circumferential direction around the first membrane portion 3. In particular, the actuators 103 are configured to apply a force along the z-axis (e.g., the optical axis) on the mask 5, thereby adjusting 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 periphery of the first membrane portion 3 (or along the opening 5a). By adjusting the position of the mask 5 along the z-axis, the shape of the first membrane portion is adjusted, which in turn determines the final shape of the optical surface 1a of the optical component 1 produced by the device 100 due to the fact that the liquid material 4 contacts the surface 3a of the first membrane portion 3 and therefore takes the shape of the surface 3a of the first membrane portion 3.

[0163] Furthermore, it is preferable to include a curing unit 102 such as a UV light for generating UV light 8 (or a heater for heating the liquid material 4). The curing unit 102 is arranged to cure the liquid material 4 after the shape of the first film portion 3 is adjusted by the actuator 103, as shown in Fig. 12, for example.

[0164] The method according to the invention allows for the cost-effective and rapid production of customized optical surfaces with high optical quality.

[0165] 13 shows in a schematic cross-section an exemplary embodiment of a method for manufacturing at least one optical component, in which the shape of the first surface 4a is defined by a piston 71. The piston 71 and the first membrane portion 3 delimit, on two opposite sides, a cavity 2 provided in step a1) of the method. A mask 5 delimits the cavity 2 laterally.

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

[0167] A 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 towards or against 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 defined by the shape of the piston 71. The piston 71 may comprise a rigid lens having a shape that forms a counterpart (counterpart) of the desired shape of the second surface 4b. In particular, the rigid lens of the piston 71 can be made according to method steps a1), b1), c1), d1) and e1).

[0169] In step d1) of the method, the liquid material 4 is hardened such that the liquid material 4 becomes a rigid material 40 and the first surface 4a becomes a first interface 40a, where the shape of the first interface 40a is defined by the shape of the first surface 4a. The liquid material is hardened by UV radiation 8 emitted by a curing unit 102 and incident on the cavity through a mask 5 that is transparent to the UV radiation 8.

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

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

[0172] 14a and 14b show in schematic cross-sectional views an exemplary embodiment of a method for manufacturing at least one optical component, in which a further interface 4c is created.

[0173] As shown in FIG. 14a, in step a1) of the method, a cavity 2 is provided. The cavity 2 is bounded on opposite sides by a first membrane part 3 and a carrier 9. In particular, the carrier 9 may be an optical element 11, such as a lens with a curved surface. Alternatively, the carrier 9 may be a flat, transparent carrier. A mask 5 bounds the cavity 2 laterally. The mask 5 comprises bellows 53 which bound the cavity laterally. The mask 5 may be moved along the z-direction to adjust the shape of the first membrane part 3. The mask 5, in particular the bellows 53, provides a flexible and in particular liquid-tight connection between the side wall 54 and the first membrane part 3a.

[0174] The side walls 54 circumferentially surround the carrier 9 laterally (along the xy plane). The carrier is movable in the Z direction. In particular, the carrier is mounted on a positioning unit 93 arranged to move the carrier 9 along the z axis. The positioning unit may be provided with a screw thread, 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 concave. The shape may also be adjusted by changing the relative pressure between the cavity 2 and the region of the side of the first membrane 3 facing the cavity. Alternatively, the shape may also be adjusted by moving the mask 5 along the z direction. Furthermore, the shape of the first membrane portion 3a may also 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 the liquid material 4 becomes a rigid material 40 and the first surface 4a becomes a first interface 40a, where the shape of the first interface 40a is defined by the shape of the first surface 4a.

[0177] After method step d1), the position of the carrier 9 is adjusted along the z-direction, whereby the rigid material remains in contact with the carrier 9. Thus, a further region 21 is created in the cavity 2, which further region 21 is bounded on one side by a first interface 40a.

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

[0179] In method step c2), the shape of the further surface 4c of the further liquid material is adjusted. The further surface 4c is arranged on the side of the further liquid material 41 facing the interface 40a, 40c created in the previous method step d1) or d2). The shape of the further surface can be adjusted by the same means as in method step c1).

[0180] In step d2) of the method the further liquid material 41 is hardened so 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 being 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(s) 40c 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 arranged adjacent to each other have different refractive indices, whereby the further interface(s) 40c form a refractive interface. In particular, the optical component is achromatic or apochromatic.

[0182] FIG. 15 shows in a schematic cross-sectional view 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 measurement unit 120.

[0183] In step a1) of the method, a cavity 2 is provided, which is defined by a first membrane portion 3 and a second membrane portion 6 on opposite sides of the cavity. A mask 5 defines the cavity 2 laterally (along the XY plane).

[0184] In step b1) of the method, the liquid material 4 is filled into the cavity 2 via the channel 7. The channel 7 connects the cavity 2 with a 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 areas adjacent to the first membrane portion 3 (pressure P2) and the second membrane portion 6 (pressure P3) and the cavity 2. The flow channel 7 may remain open during step c1) of the method to allow the liquid material 4 to flow between the cavity 2 and the reservoir 55. In particular, the reservoir 55 and the cavity 2 have the same pressure value P1. The reservoir 55 may remain open to normal pressure. The ratio of P1 to P2 may be determined independently of the ratio of P1 to P3. Because the cavity 2 remains at a constant pressure value P1, the shape of the first surface can be controlled independently from the shape of the second surface by adjusting the pressure values ​​P2 and P3. Thus, a change in the shape of the first or second surface induces a flow of the liquid material through the flow channel 7. Advantageously, adjusting the shape of the first surface does not affect the shape of the second surface, and vice versa.

[0186] The measurement unit 120 is arranged to measure the shape of the first and second surfaces 4a, 4b by means of a measurement beam 123 transmitted through the first and second surfaces 4a, 4b. Alternatively, the measurement unit 120 may be arranged to measure the shape of the first / second surfaces (4a, 4b) by reflection at the first and / or second surfaces. In particular, the measurement unit 120 comprises 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 a first interface 40a, and the second surface 4b becomes a second interface 40b. The UV radiation is directed toward 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. FIG. 16 shows, in a schematic cross-sectional view, an exemplary embodiment of a method for manufacturing at least one optical component, in which the shape of the second surface 4b is defined by an actuation unit 101. In particular, the actuation unit 101 is arranged to define positions of discrete points of the second surface 4b along the z-axis. The actuation unit 101 comprises a plurality of actuators 103 arranged to press against the second membrane portion 6. In particular, the actuators comprise pins that contact the second membrane portion, and the positions of the pins along the z-axis are 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 stepper motor, or a hydraulic actuator.

[0188] The pressure P1 of the liquid material 4 remains constant during step c1) of the method. In particular, the 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) providing at least one cavity (2), said at least one cavity (2) being bounded on a first side by a surface (3a) of a first membrane portion (3), the shape of said first membrane portion (3) being adjustable, and further comprising providing a carrier (9), in particular a carrier (9) for holding said at least one optical component (1), b1) filling the at least one cavity (2) with a liquid material (4), wherein the liquid material (4) is filled into the at least one cavity (2) so that the liquid material (4) contacts the surface (3a) of the first membrane portion (3); c1) adjusting the shape of the first surface (4a) of the liquid material (4) by adjusting the shape of the first film portion (3); d1) hardening the liquid material (4) filled in the at least one cavity (2) so that the liquid material (4) becomes a rigid material (40) and the first surface (4a) becomes a first interface (40a), wherein the shape of the first interface (40a) is determined by the shape of the first surface (4a), and further comprising removing the carrier (9) from the rigid material (40), or the carrier (9) is fixedly attached to the rigid material (40), and the carrier (9) forms a mount for the at least one optical component (1); and e2) the optical component comprises the rigid material (40) and the first interface (40a) is an optical surface of the optical component (1); The method comprising:

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

3. 3. The method according to claim 1, wherein the at least one cavity (2) is formed by an opening (5a) formed in a mask (5), and the first membrane portion (3) is connected to the mask (5) and covers the opening (5a) so as to define the at least one cavity (2) on the first side.

4. 4. The method according to claim 3, wherein the mask (5) comprises at least one channel (7), via which the at least one cavity (2) is filled with the liquid material (4).

5. 5. The method according to claim 3 or 4, wherein after method step d1), the mask (5) retains the rigid material (40).

6. 6. The method according to any one of claims 1 to 5, comprising a method step e1), in which adhesion of the optical component to the first interface (40a) is reduced by a coating applied on the first interface (40a) or on the first film portion (3) arranged between the first interface (40a) and the optical component (1), or by a nanostructure formed by the first interface (40a).

7. 6. The method according to any one of claims 1 to 5, comprising method step e2), wherein reflection of light in the visible wavelength range at the first interface (40a) is reduced by a coating applied on the first interface (40a) or the first film portion (3), or by a nanostructure formed by the first interface.

8. 4. The method of claim 3, wherein the method comprises method step e2) and an optical element (11) is provided on the side of the mask (5) facing away from the first surface (4a).

9. 9. The method of claim 8, wherein the optical element (11) has a refractive index essentially equal to the refractive index of the rigid material (40) and / or the optical element (11) comprises the same material as the rigid material (40).

10. 10. The method according to claim 8 or 9, wherein in method step d1) the optical element (11) is bonded to the rigid material (40).

11. 11. The method according to claim 8, wherein the optical element (11) comprises a curved optical surface (11a), and the curved optical surface (11a) faces away from the rigid material (40) filled in the at least one cavity (2).

12. The method comprises a method step e2), wherein the at least one cavity (2) is bounded on a second side opposite the first side by a surface (6a) of a second membrane part (6), the shape of the second membrane part (6) being adjustable; Step b1) further comprises filling the at least one cavity (2) with the liquid material (4) so ​​that the liquid material (4) also contacts the surface (6a) of the second membrane portion (6); Step c1) further comprises adjusting the shape of the second membrane portion (6), Step d1) further comprises hardening the liquid material (4) filled in the at least one cavity (2) so 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 claim 1 or 3.

13. 2. The method of claim 1, wherein the carrier (9) is a printed circuit board.

14. 14. The method according to claim 1 or 13, wherein the carrier (9) comprises 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 form-fitting manner.

15. 15. The method according to claim 14, wherein the at least one opening (9a) in the carrier (9) forms an aperture of the at least one optical component (1).

16. the carrier (9) is a transparent carrier having a first side (91) facing the liquid material (4) filled into the cavity in step b1) of the method and a second side (92) facing away from the first side of the carrier (9); the support (9) separates the at least one cavity (2) into a first region (2a) starting from the first side (91) and extending in a direction opposite to the support (9) and a second region (2b) starting from the second side (92) and extending in a direction opposite to the support (9); wherein step b1) further comprises filling the at least one cavity (2) with the liquid material (4) so ​​that the liquid material (4) contacts the first side (91) of the carrier (9); and Step d1) further comprises hardening the liquid material (4) in the first region (2a) so that the rigid material (40) is bonded to the first side (91) of the carrier (9).

15. The method of claim 1 or 14.

17. The method comprises the further steps of: b2) filling the second region (2b) of the at least one cavity (2) with the liquid material (4) so ​​that the liquid material contacts the second side (92) of the carrier (9); c2) adjusting the shape of the second surface (4b) of said liquid material (4) in said second region (2b); d2) hardening the liquid material (4) filled in the second region (2b) so 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 determined by the shape of the second surface (4b) and so that the rigid material (4) is bonded to the second side (92) of the carrier (9); Including, 17. The method of claim 16, wherein method steps b2), c2) and d2) are performed in the order listed after method step d1).

18. Process step c1) and / or process step c2) may comprise: - deforming said mask (5); - applying pressure to the mask (5) at several points on the mask (5) simultaneously; - adjusting the pressure (P1) of said liquid material (4) and / or the ambient pressure (P2, P3) outside said at least one cavity (2); - sucking or pressing the first membrane part (3) onto the mould and / or sucking or pressing the second membrane part (6) onto the mould; - pressing a master onto said first membrane part (3) and / or pressing a master onto said second membrane part (6); - changing the distance between the first and second parts (51, 52) of said mask (5); - changing the distance between said first membrane portion (3) and said 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 partly determined by the centrifugal force applied to the liquid material; The method of claim 12 , comprising at least one of:

19. 19. The method according to any one of claims 1 to 18, wherein in method steps c1), c2), d1) and / or d2) the shape of the first surface (4a) and / or second surface (4b) is measured.

20. The method according to any one of the preceding claims, wherein the shape of the first surface (4a) and / or the second surface (4b) is iteratively adjusted.

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

22. 22. The method according to any one of claims 1 to 21, wherein in method step d1) and / or method step d2), small areas of the liquid material (4) of the at least one optical component (1) are successively hardened.

23. The method according to any one of the preceding claims, wherein in method step d1) and / or method step d2) the liquid material (4) is heated for hardening.

24. 4. The method of claim 3, wherein the mask (5) is removed after hardening of the liquid material (4) of the at least one optical component (1).

25. 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), wherein for each of the plurality of cavities (2), the liquid material (4) forms a respective first surface (4a); In step c1) of the method, the shape of the first surfaces (4a) is adjusted; and 25. The method according to any one of claims 1 to 24, wherein in step d1), the liquid material (4) is hardened so that it becomes a rigid material (40) and the plurality of first surfaces (4a) become a plurality of first interfaces (40a), wherein the shapes of the plurality of first interfaces (40a) are respectively defined by the shapes of the plurality of first surfaces (4a).

26. 26. The method of claim 25, wherein the optical component (1) is a lens array comprising a plurality of lenses, and each first interface (40a) defines the shape of a refractive surface of one of the lenses.

27. 26. The method according to claim 25, wherein after hardening of the liquid material (4), excess material between adjacent lenses is removed, in particular unhardened liquid material (4).

28. In method step f1), the lenses of the lens array are separated by at least one of milling, laser cutting, stamping, cutting, and punching; 27. The method of claim 26, wherein method step f1) is performed after method step d1).

29. After step d1) of the method, In method step b2), a further liquid material is filled into said at least one cavity, said further liquid being adjacent to the interface created in the preceding method step d1) or d2), In step c2) of the method, the shape of a further surface (4c) is adjusted, said further surface (4c) being arranged on the side of said further liquid material facing the interface (40a) created in step d1) or d2) of the preceding method; and 18. The method according to claim 17, wherein in method step d2) the further liquid material is hardened such that it becomes a further rigid material and the further surface (4c) becomes a further interface (40c), wherein the shape of the further interface (40c) is defined by the shape of the further surface (4c).

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