Diffractive optical elements
AssigneeMems Optical, Inc.
InventorGregory Hambright
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Abstract
A method for the replication of diffractive optical elements using audio/video disc manufacturing equipment and processes. The audio/video disc manufacturing process and mold mastering tooling create diffractive optical elements using a mold plate. The diffractive optic design and photomasks are first fabricated then replicated using compact disc industry mold mastering techniques. The surface relief pattern is produced centered in the plate using ion milling or refractive ion etching photolithographic fabrication techniques. Once patterned, the mold master plate is punched into a circular form consistent with standard compact or video disc mold bases--typically eight inches for a compact disc. After molding, each element can be cut out of the disc using blade, shear, waterjet or laser cutting.
Claims13
A method of manufacturing a plurality of separate optical elements, said method comprising the steps of:
- forming a plurality of patterns in an ordered array on a first element;
- using said first element to produce a mold master element having a plurality of negative patterns in an ordered array, wherein said negative patterns correspond to the patterns on said first element;
- using said mold master element to form a plurality of annular plates, with each of said plates having a plurality of molded optical elements, wherein said molded optical elements have molded patterns corresponding to the plurality of patterns on said first element, and wherein said molded optical elements are located in ordered arrays in said annular plates, and wherein said ordered arrays of said molded optical elements correspond to said ordered array of said patterns on said first element;
- and
- wherein said method further comprises the step of separating said molded optical elements from each other, said separating step including the step of cutting through said annular plates along lines defined by said ordered arrays of said molded optical elements.
A method of manufacturing optical elements, the method comprising the steps of:
- creating a mold master having a negative of at least one optical pattern;
- using the mold master with audio/video disc manufacturing equipment to mold optical elements in annular plates, such that said annular plates each contain at least one optical element and a central hole, and such that the molded surfaces of said optical elements correspond to the optical pattern of said mold master;
- and
- wherein said manufacturing method further comprises the step of subsequently cutting said optical elements from said annular plates.
Dependencies are inferred from the claim text.