Patent ID: 9011742
Filing Date: 2015-04-21
Classification: B29C,B29D,B29L,G02B,Y10T

Abstract:
1. A replication method for manufacturing a plurality of optical elements having a structured surface with structural features, comprising the steps of: a. providing a first replication tool having, on a first replication surface, negative structural features being a negative of at least some of the structural features, b. providing a substrate comprising a first surface and a second surface opposed to the first surface, c. providing replication material in a plastically deformable or viscous or liquid state, d. moving the first replication tool and the substrate against each other with the replication material between the first surface and the first replication surface, e. controlling and stopping a flow of replication material using a spacer portion of the first replication tool, protruding from the replication surface to stop the flow so that isolated replication areas with the replication material arise, the replication material in the isolated replication areas in contact with the first replication surface and the first surface, wherein the spacer portion comprises a plurality of spacer rings and is laid out in a manner that the fluid dynamics during the replication process is controlled to form said isolated replication areas, f. hardening the replication material, g. removing the first replication tool, h. providing a second replication tool having, on a second replication surface, negative structural features being a negative of at least some of the structural features, i. providing further replication material in a plastically deformable or viscous or liquid state, j. moving the second replication tool and the substrate against each other with the further replication material between the second surface and the second replication surface, wherein the step of moving comprises aligning the second replication tool with the hardened replication material adhering to the second surface, k. hardening the further replication material, and l. removing the second replication tool, m. wherein the plurality of optical elements comprises the hardened replication material adhering to the first surface of the substrate and the hardened further replication material adhering to the second surface of the substrate.