# US 7,628,940 B2 · Method for manufacturing three dimensional optical components > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 7,628,940 B2 - Document ID: US7628940B2 - Status: Granted - Kind: B2 - Application number: 11/051,652 - Filed: 2005-02-04 - Published: 2005-08-11 - Granted: 2009-12-08 - Earliest claimed: 2004-02-09 - Assignees: Upstream Engineering Oy - Inventors: Mikko Petteri Alasaarela; Ilkka Antero Alasaarela - Web page: https://patentgrep.com/patent/US7628940B2 ## CPC - B29D 7/01: Films or sheets - B29D 11/00: Producing optical elements, e.g. lenses or prisms (grinding or polishing of optical elements B24B; constructional form of optical elements G02B; {optical parts of spectacles G02C7/00}) - G02B 5/06: Fluid-filled or evacuated prisms - B29C 48/12: Articles with an irregular circumference when viewed in cross-section, e.g. window profiles - B29C 48/13: Articles with a cross-section varying in the longitudinal direction, e.g. corrugated pipes - B29C 53/00: Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor (B29C61/10 takes precedence) - B29C 69/00: Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore {(B29C48/001 takes precedence)} - Y10T 156/1051: by folding - B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00) - G02B: OPTICAL ELEMENTS, SYSTEMS OR APPARATUS - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract Disclosed is a method for manufacturing an optical component in three dimensions. In one aspect, the method includes providing a substrate that includes contiguous rigid plates that are disposed such that a major surface of each rigid plate lies substantially in a single plane. At least one of said surfaces is characterized by a micro-optical structure. Further in the method, the substrate is folded such that the at least one surface having a micro-optical structure and at least one other of the above-recited surfaces are disposed at an angle to one another. A second method is also disclosed. Disclosed structures made by the method(s) include a mesa structure with a top plate and four sidewall plates, each facing a reflective plate, as well as closed structures such as cubes and rectilinear boxes into which separate plates may be disposed. A mold for preferentially making the substrate such as by injection molding is also detailed. ## Claims ### Claim 1 A method for manufacturing an optical component in three dimensions comprising: providing a substrate comprising contiguous rigid plates and arranged such that a major surface of each rigid plate lies substantially in a plane, wherein at least one of said surfaces is characterized by a micro-optical structure; folding the substrate such that the at least one surface having a micro-optical structure and at least one other said surface are disposed at an angle to one another, wherein at least two of said rigid plates define one of a protrusion and a recession in one of the said major surface and an opposed major surface that, when folded, form a support structure for a separate optical plate. ### Claim 2 (depends on 1) The method of claim 1 wherein the substrate comprises at least three rigid plates, and wherein folding the substrate comprises folding such that the at least one surface having a micro-optical structure and at least two other said surfaces are each disposed at an angle to one another. ### Claim 3 (depends on 1) The method of claim 1 wherein the micro-optical structure is selected from at least one of the set: refractive micro-optical structure, reflective micro-optical structure, micro-prism, micro-mirror, micro-lens, Fresnel lens, Fresnel mirror, diffraction grating, and optical thin film stack. ### Claim 4 (depends on 1) The method of claim 1 wherein the substrate comprises a flexible film affixed to the rigid plates. ### Claim 5 (depends on 4) The method of claim 4 wherein the micro-optical structure is in the flexible film. ### Claim 6 (depends on 4) The method of claim 4 wherein the micro-optical structure is along a surface of a rigid plate. ### Claim 7 (depends on 1) The method of claim 1 wherein providing a substrate comprises forming the micro-optical structure while forming the substrate by an injection molding process. ### Claim 8 (depends on 1) The method of claim 1 wherein providing the substrate comprises molding the substrate and separately forming the micro-optical structure in the substrate. ### Claim 9 (depends on 1) The method of claim 1, wherein providing the substrate comprises adding one or more optical coatings on a surface thereof. ### Claim 10 (depends on 1) The method of claim 1 wherein the substrate defines grooves between each rigid plate. ### Claim 11 (depends on 10) The method of claim 10 wherein folding comprises folding the substrate along the said grooves. ### Claim 12 (depends on 10) The method of claim 10 further comprising, after folding: securing at least some mating plate edges to one another by one of adhesion and localized melting. ### Claim 13 (depends on 1) The method of claim 1 wherein all surfaces of a completed optical component that include micro-optics lay substantially in the said plane prior to folding, or in another plane that is, prior to folding, parallel to said plane. ### Claim 14 (depends on 1) A method of claim 1, further comprising: inserting a separate optical plate after the folding so as to be supported by the support structure. ### Claim 15 (depends on 1) The method of claim 1, wherein folding the substrate comprises folding so as to define a volume, the method further comprising: at least partially filling the volume with a material having an intended index of refraction. ### Claim 16 (depends on 15) The method of claim 15, wherein filling the volume comprises disposing the folded substrate against an assembly mold and injecting under pressure the material having an intended index of refraction. ### Claim 17 (depends on 16) The method of claim 16, wherein injecting under pressure is through a via in the assembly mold. ### Claim 18 (depends on 16) The method of claim 16, wherein the material having an intended index of refraction is plastic, liquid or gel. ### Claim 19 (depends on 1) The method of claim 1 wherein at least five surfaces each have a micro-optical structure, and folding comprises folding such that each of the at least five surfaces are disposed at an angle to one another. ### Claim 20 (depends on 19) The method of claim 19 wherein said at least five surfaces define a mesa structure after folding. ### Claim 21 (depends on 1) The method of claim 1 wherein folding comprises folding the substrate into a hollow closed structure. ### Claim 22 (depends on 21) The method of claim 21 wherein the structure is substantially rectangular. ### Claim 23 A method comprising, providing a substrate comprising contiguous rigid plates and arranged such that a major surface of each rigid plate lies substantially in a plane, wherein at least one of said surfaces is characterized by a micro-optical structure; and folding the substrate such that the at least one surface having a micro-optical structure and at least one other said surface are disposed at an angle to one another, wherein providing the substrate comprises molding the substrate and separately forming the micro-optical structure in the substrate, and wherein separately forming the micro-optical structure is by hot-embossing or by UV-embossing. ### Claim 24 A method, comprising: providing a substrate comprising contiguous rigid plates and arranged such that a major surface of each rigid plate lies substantially in a plane, wherein at least one of said surfaces is characterized by a micro-optical structure; folding the substrate such that the at least one surface having a micro-optical structure and at least one other said surface are disposed at an angle to one another, wherein at least five surfaces each have a micro-optical structure, and folding comprises folding such that each of the at least five surfaces are disposed at an angle to one another, and wherein said at least five surfaces define a mesa structure after folding; disposing a light source within a cavity defined by the mesa structure; and substantially filling said cavity with an optical material having a desired refractive index. ### Claim 25 A method for manufacturing an optical component in three dimensions comprising: providing a substrate comprising contiguous rigid plates and arranged such that a major surface of each rigid plate lies substantially in a plane, wherein at least one of said surfaces is characterized by a micro-optical structure; folding the substrate such that the at least one surface having a micro-optical structure and at least one other said surface are disposed at an angle to one another, wherein at least five surfaces each have a micro-optical structure, and folding comprises folding such that each of the at least five surfaces are disposed at an angle to one another, wherein said at least five surfaces define a mesa structure after folding; and disposing a plurality of additional plates, each having a reflective surface, about the mesa structure such that each surface that defines a sidewall of the mesa structure faces a reflective surface. ### Claim 26 (depends on 25) The method of claim 25, wherein the additional plates are additional rigid plates of the substrate, and the disposing comprises folding the additional plates relative to the said five surfaces. ### Claim 27 (depends on 25) The method of claim 25 further comprising: filling, with an optical material having a desired refractive index, a volume bounded at least in part by the facing reflective surfaces and the sidewalls of the mesa structure. ### Claim 28 A method comprising, providing a substrate comprising contiguous rigid plates and arranged such that a major surface of each rigid plate lies substantially in a plane, wherein at least one of said surfaces is characterized by a micro-optical structure; and folding the substrate such that the at least one surface having a micro-optical structure and at least one other said surface are disposed at an angle to one another, wherein folding comprises folding the substrate into a hollow closed structure and, wherein folding further comprises, prior to closing the structure, disposing a substantially planar cross member within the structure that diagonally bisects said closed rectangular structure. ### Claim 29 (depends on 28) The method of claim 28 wherein folding further comprises, prior to closing the structure, disposing two substantially planar cross members within the structure, each of said cross members diagonally bisecting said rectangular closed structure and intersecting one another.