Abstract:
A method for forming an optical component includes (i) depositing optical layers on a base, and (ii) controlling a thickness of a tuning layer by (a) depositing the tuning layer on the optical layers, (b) measuring a first optical characteristic, (c) measuring a second optical characteristic after continued deposition of the tuning layer, (d) determining whether the second optical characteristic has decreased compared to the first optical characteristic, (e) when the second optical characteristic has not decreased, continuing deposition of the tuning layer and returning to steps (ii)(b)-(e), when the second optical characteristic has decreased, terminating the depositing and removing a portion of the tuning layer formed during a period of time defined from when an increase/decrease of the second optical characteristic is stopped to when the second optical characteristic is changed to be decreased, and (f) adding a layer of a lower refractive index on the tuning layer.

Description:
RELATED APPLICATION DATA 
     The present application claims priority to Japanese Applications No. P11-294406 filed Oct. 15, 1999, which application is incorporated herein by reference to the extent permitted by law. 
     BACKGROUND OF THE INVENTION 
     The present invention relates to an apparatus and a method for producing an optical component by forming a multi-layer film on a base. 
     To realize good optical characteristics of an optical component comprised of an optical film, such as a dichroic mirror, the optical film is required to be of a multi-layer structure having at least ten optical thin layers. The optical thin layer is formed by a low refractive index material such as MgF 2  or SiO 2  or a high refractive index material such as TiO 2  or Nb 2 O 5 . A usual batch process used for producing an optical component comprised of an optical film having a multi-layer structure of optical thin layers involves evaporating raw materials for the optical thin layers in a vacuum system in accordance with a vapor-deposition process or sputtering process, to form the optical thin layers on a transparent member such as a glass board. 
     One example of a related art method of producing an optical component by forming an optical film having a multi-layer structure of optical thin layers has been disclosed in Japanese Patent Laid-open No. Hei 11-119002. 
     In accordance with this method, optical thin layers are continuously formed on a base, typically, a film in such a manner that the configuration of the optical thin layers is adjusted to a predetermined optically designed configuration as a whole, by forming the optical thin layers on the base, and simultaneously controlling a thickness of each layer to satisfy a specific light transmission characteristic by using, for example, an optical monitor. 
     The method disclosed in the above document, Japanese Patent Laid-open No. Hei 11-119002, however, has the following problems: namely, since the method fails in means for accurately measuring a thickness of each of optical thin layers continuously formed on the base such as film, the thickness of the optical thin layer intended to be adjustably formed is, really, inaccurately measured. This gives rise to not only a problem that the optical component produced by this method cannot exhibit ideal optical characteristics due to a deviation of the thickness of each optical thin layer from the ideal thickness, but also a problem that a variation in optical characteristics occurs between optical components produced by this method. 
     For example, as shown in FIG. 14, when each optical thin layer is formed at a usual formation rate in accordance with the related art method, an optical characteristic represented by a light transmittance is largely changed due to a change in thickness of the optical thin layer. In the figure, values “74.76 nm”, “194.76 nm”, and “114.76 nm” designate the thicknesses of the optical thin layers. Even when each optical thin layer is formed at a formation rate slower than the usual rate in accordance with the related art method, as shown in FIG. 15, an optical characteristic represented by a light transmittance is largely changed due to a change in thickness of the optical thin layer. In the figure, values “0 nm”, “65.5 nm”, “97.3 nm” and “112.4 nm” designate the thicknesses of the optical thin layers. 
     The above related art method has a further problem that since the film thickness adjustment is performed for each of optical thin layers constituting an optical film, it takes a lot of time to form the optical film composed of the optical thin layers. 
     SUMMARY OF THE INVENTION 
     An object of the present invention is to provide an apparatus and a method for producing an optical component, each of which is capable of easily, stably producing an optical component having good optical characteristics. 
     To achieve the above object, according to a first aspect of the present invention, there is provided an optical component producing apparatus for forming a multi-layer film, which is composed of alternately stacked layers different in optical characteristic, on a base, the apparatus including: film formation means for forming the multi-layer film on the base; measurement means for measuring an optical characteristic of the optical component obtained by forming the multi-layer film on the base; and control means for controlling a thickness of a portion of the multi-layer film formed by the film formation means on the basis of the measured optical characteristic of the optical component. 
     According to a second aspect of the present invention, there is provided an optical component producing method for forming a multi-layer film, which is composed of alternately stacked layers different in optical characteristic, on a base, the method including: measuring an optical characteristic of the optical component obtained by forming the multi-layer film on the base; and controlling, on the basis of the measured optical characteristic of the optical component, a thickness of a portion of the multi-layer film to be formed on the base. 
     With these configurations, layers of a multi-layer film are formed one by one on the base (by the film formation means), wherein an optical characteristic of an optical component obtained by forming the multi-layer film on the base is measured (by the measurement means), and a portion of the multi-layer film formed by the film formation means is controlled (by the control means) on the basis of the measured optical characteristic of the optical component. Here, by selecting a portion exerting the largest effect on the optical characteristic of the optical component as the above portion of the multi-layer film, the optical component having a good optical characteristic can be formed. Further, since the thickness of only a portion of the multi-layer film is measured, the film thickness control can be easily performed. As a result, it is possible not only to produce an optical component having a good optical characteristic but also to produce a plurality of optical components without a variation in optical characteristic therebetween. 
     In the apparatus according to the first aspect of the present invention, preferably, the measurement means measures a transmittance of the optical component, and the control means terminates the film formation by the film formation means at the portion of the multi-layer film when the measured transmittance of the optical component is changed to be decreased. 
     In the method according to the second aspect of the present invention, preferably, the measurement step includes the step of measuring a transmittance of the optical component; and the control step includes the step of terminating the film formation at the portion of the multi-layer film when the measured transmittance of the optical component is changed to be decreased. 
     With these configurations, the transmittance of the optical component is measured (by the measurement means), Id and the film formation (by the film formation means) at the portion of the multi-layer film is terminated when the measured transmittance of the optical component is changed to be decreased. As a result, an optical component, which is composed of the multi-layer film exhibiting a good optical characteristic formed on the base, can be obtained. 
     The above preferable apparatus, specifying the transmittance as the optical characteristic, according to the first aspect of the present invention, may further include removal means for removing the layer portion formed during a period of time from a time point when the increase/decrease of the measured transmittance of the optical component is stopped to a time point when the measured transmittance is changed to be decreased. 
     The above preferable method, specifying the transmittance as the optical characteristic, according to the second aspect of the present invention, may further include a removal step of removing a layer portion formed during a period of time from a time point when the increase/decrease of the measured mean light transmittance of the optical component is stopped to a time point when the measured mean light transmittance is changed to be decreased. 
     With these configurations, since a layer portion formed during a period of time from a time point when the increase/decrease of the measured transmittance of the optical component (by the measurement) is stopped to a time point when the measured transmittance is changed to be decreased is removed (by the removal means), the layer thickness can be finely adjusted. As a result, it is possible to produce an optical component capable of more accurately exhibiting a good optical characteristic. 
     In the apparatus according to the first aspect of the present invention, preferably, the control means controls a thickness of one layer of the plurality of alternately stacked layers, the one layer having a higher refractive index and being positioned near the uppermost surface remotest from the base. 
     In the method according to the second aspect of the present invention, preferably, the control steps include the step of controlling a thickness of one layer of the plurality of alternately stacked layers, the one layer having a higher refractive index and being positioned near the uppermost surface remotest from the base. 
     With these configurations, a thickness of one layer of the plurality of alternately stacked layers constituting the multi-layer film is controlled (by the control means). The one layer has a higher refractive index and is positioned near the uppermost surface remotest from the base. It has been found by the present inventors that, of the plurality of alternately stacked layers, one layer having a higher refractive index and being positioned near the uppermost surface remotest from the base exerts a large effect on the optical characteristic of the optical component. As a result, by controlling the thickness of such a layer (by the control means), it is possible to produce an optical component having a good optical characteristic. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a plan view showing a configuration example of an optical thin layer forming apparatus as a preferred embodiment of the present invention; 
     FIG. 2 is a block diagram showing a configuration example of an optical monitor shown in FIG. 2; 
     FIG. 3 is a sectional view showing one example of a cross-sectional structure of an optical component formed by the optical thin layer forming apparatus; 
     FIGS. 4A to  11 B are characteristic diagrams showing examples of transmittance distributions relative to wavelengths of light; 
     FIG. 12 is a diagram showing an actual change in mean transmittance in the case of gradually increasing the thickness of an optical thin layer by using the optical monitor; 
     FIG. 13 is a diagram showing one example of a difference in final transmittance distribution between an optical component in which the thickness adjustment by using the optical monitor is performed and an optical component in which the thickness adjustment by using the optical component is not performed; 
     FIG. 14 is a characteristic diagram showing one example of a transmittance distribution relative to wavelengths of light for an optical component formed by a related art optical thin layer producing method; and 
     FIG. 15 is a characteristic diagram showing one example of a transmittance distribution relative to wavelengths of light for an optical component formed by the related art optical thin layer producing method. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Hereinafter, a preferred embodiment of the present invention will be described with reference to the accompanying drawings. 
     FIG. 1 is a plan view showing a configuration example of an optical thin layer forming apparatus  1  as a preferred embodiment of the present invention. 
     The optical thin layer forming apparatus or optical component producing apparatus  1  is used for forming optical thin layers on a base such as a high polymer film. Specific examples of the optical components produced by the apparatus  1  may include an dichroic mirror used for a projection television, an UV-IR filter (ultraviolet rays and infrared rays cutting filter), and a band filter. The following description will be made by using a dichroic mirror as an optical component. 
     The optical thin layer forming apparatus  1  has a feed roll  4  (film formation means), a winding roll  6  (film formation means), guide rolls  5   a ,  5   b ,  5   c ,  5   d ,  5   e , and  5   f  (film formation means), a plasma electrode  8  (film formation means), evaporation sources  7   a  and  7   b  (film formation means), and an optical monitor  10  (measurement means). A gas lead valve  9  and an evacuation system  2  are connected to the apparatus  1 . Preferably, the apparatus  1  has removal means  27 . 
     A running system (film formation means) runs at a constant speed, a base  3   a  from the feed roll  4  to the winding roll  6  by way of the guide rolls  5   a ,  5   b ,  5   c ,  5   d , and  5   f . The plasma electrode  8 , which is used for preparation such as degassing of the base  3   a , is opposed to a portion, disposed between the guide rolls  5   a  and  5   b , of the base  3   a . The evaporation sources  7   a  and  7   b , each of which is configured typically as a sputtering system, are disposed with their targets opposed to the guide roll  5   d . The target is made from Si, Nb or the like as an optical thin layer material. 
     The gas lead valve  9 , which is connected to the apparatus  1 , is used for adjusting, upon sputtering, the flow rate of a reaction gas to be supplied in the apparatus  1  such as argon (Ar) gas or oxygen gas. While not shown, the guide roll  5   d  has a cooled structure for preventing the temperature rise of the base  3   a  upon film formation. 
     The optical monitor  10  is used for measuring an optical characteristic of an optical component obtained by forming optical thin layers on the surface of the base  3   a . The optical characteristic to be measured is represented by a light transmittance, preferably, a mean light transmittance of an optical component. Since the apparatus  1  has the optical monitor  10 , it can accurately measure a mean light transmittance of an optical component obtained by forming a multi-layer film having a plurality of optical thin layers. 
     The removal means  27 , which is operated by a control unit  25 , is used for removing an excess layer portion formed in a period of time from a time point at which the increase/decrease of a mean light transmittance measured by the optical monitor  10  is stopped to a time point at which the mean light transmittance is changed to be decreased. With this configuration, since the apparatus  1  can remove the above excess layer portion, the layer thickness can be finely adjusted. Accordingly, the apparatus  1  can produce an optical component having a good optical characteristic. 
     FIG. 2 is a block diagram showing a configuration example of the optical monitor  10  shown in FIG.  1 . 
     The optical monitor  10  includes an optical source  10   c , an optical head  10   g , and a spectroscope  10   d . The optical monitor  10  preferably further includes a switch  10   f . These devices are connected to each other via optical communication lines such as optical fibers except for a signal line for connecting the spectroscope  10   d  to the control unit  25 . 
     The optical head  10 g has a light emitting unit  12  and a light receiving unit  13 . The light emitting unit  12  is a light source enabling continuous emission of light having a wavelength of 450 to 700 nm, that is, a light source having a continuous spectrum of 450 to 700 nm in wavelength. The light emitting unit  12  is configured as an LED (Light Emitting Device). The light receiving unit  13  is configured as a photodiode for detecting a continuous spectrum of 450 to 700 nm in wavelength. The light emitting unit  12  and the light receiving unit  13  are opposed to each other with the running base  3   a  put therebetween. The light emitting unit  12  is connected to the light source  10   c . The light source  10   c , in principle, supplies a specific quality of light. An optical communication line  10   b  extending from the switch  10   f  is connected to a mid point of the communication line between the light emitting unit  12  and the light source  10   c.    
     The light receiving unit  13  is connected to the spectroscope  10   d , and preferably, the switch  10   f  to which the optical communication line  10   b  is connected is provided between the light receiving unit  13  and the spectroscope  10   d . The light receiving unit  13  receives a light component, passing through the base  3   a , of light emitted from the light emitting unit  12 . The switch  10   f  detects a variation in quality of light emitted from the light source  10   c  by way of the optical communication line  10   b . Accordingly, if the quality of light emitted from ail the light source  10   c  varies, the spectroscope  10   d  can detect a rate of the quality of light received by the light receiving unit  13  to the quality of light emitted from the light emitting unit  12  in consideration of the increased/decreased quality of light. 
     The spectroscope  10   d  is connected to the control unit  25  and is controlled by the control unit  25 . The spectroscope  10   d  can accurately calculate a rate (transmittance) of a light component, passing through the base  3   a , of light emitted from the light emitting unit  12  by the function of the switch  10   f . The transmittance thus calculated is supplied to the control unit  25 . 
     The control unit  25  controls a thickness of a portion of the multi-layer film to be formed on the optical component on the basis of the transmittance (or mean transmittance) thus supplied thereto. Of the multi-layer film to be formed on the optical component, one film layer (tuning layer  32  in FIG. 3) having a higher refractive index and being positioned near the uppermost surface remotest from the base is controlled by the control unit  25 . The tuning layer  32 , which is a higher refractive index layer of the multi-layer film composed of layers different in refractive index to be described later, exerts a large effect on the optical characteristic of the optical component. As a result, by controlling the thickness of the tuning layer  32  by means of the control unit  25 , it is possible to produce an optical component having a good optical characteristic. 
     FIG. 3 is a sectional view showing one example of a cross-sectional structure of an optical component formed by the optical thin layer forming apparatus  1  shown in FIG.  1 . 
     An optical component includes the base  3   a , a hard coat layer  3   b , a lower refractive index layer  3   c ′, and a multi-layer film  30 , which are arranged in this order from bottom to top. The multi-layer film  30  is obtained by forming lower refractive index layers  3   c  and higher refractive index layers  3   d  one by one in such a manner that the layers  3   c  and  3   d  are alternately stacked. To be more specific, the optical component is obtained by repeating alternative stacking of the lower refractive index layers  3   a  and higher refractive index layers  3   d  by 21 times on the base  3   a  covered with the hard coat layer  3   b  via the lower refractive index layer  3   c′.    
     The determination of the position of the tuning layer  32  in the multi-layer film  30  will be described below. 
     FIGS. 4A to  11 B are characteristic diagrams showing examples of transmittance distributions relative to wavelengths of light. In these figures, the abscissa indicates the wavelength (nm) and the ordinate indicates the transmittance (%). In addition, values described beside curves showing optical characteristics in each of FIGS. 4A to  11 B designate thicknesses of the tuning layers  32 . 
     FIG. 4A shows optical characteristics for light incident on the base  3   a  in the vertical direction, which are examples of optical characteristics showing the results outputted from the optical monitor  10 , and FIG.  4 B shows optical characteristics for light incident on the base  3   a  at an angle of 45° with respect to the vertical direction, which are examples of optical characteristics of optical components (dichroic mirrors in this embodiment). 
     FIGS. 5A,  6 A,  7 A,  8 A,  9 A,  10 A and  11 A are each similar to FIG. 4A; and FIGS. 5B,  6 B,  7 B,  8 B,  9 B,  10 B and  11 B are each similar to FIG.  4 B. 
     FIGS. 4A to FIG. 7B show the transmittance characteristics relative to wavelengths of light for an optical component including the multi-layer film  30  obtained by stacking the lower refractive index layers  3   c , higher refractive index layers  3   d , lower refractive index layers  3   c , . . . , higher refractive index layers  3   d , and lower refractive index layers  3   c  in this order from bottom to top. The tuning layer  32  is set at the 18th layer in FIGS. 4A and 4B, the 19th layer in FIGS. 5A and 5B, the 20th layer in FIGS. 6A and 6B, and the 21st layer in FIGS. 7A and 7B. 
     From the optical characteristics of the dichroic mirror, it becomes apparent that depending on a change in layer thickness, the optical characteristic of the higher refractive index layer  3   d  is changed larger than the optical characteristic of the lower refractive index layer  3   c  does. Further, as the results outputted from the optical monitor  10  shown in FIGS. 4A,  5 A,  6 A and  7 A, in the case where the tuning layer  32  is taken as the 20th higher refractive index layer  3   d , the transmittance becomes the peak value at the ideal thickness in the transmission wavelength band (450 to 550 nm); while in the case where the tuning layer  32  is taken as the 18th high refractive index layer  3   d , the transmittance does not become the peak value at the ideal thickness in the transmission wavelength band (450 to 550 nm). 
     FIGS. 8A to FIG. 11B show the transmittance characteristics relative to wavelengths of light for an optical component including the multi-layer film  30  obtained by stacking the higher refractive index layers  3   d , lower refractive index layers  3   c , higher refractive index layers  3   d , . . . , lower refractive index layers  3   c  and higher refractive index layers  3   d  in this order from bottom to top. The tuning layer  32  is set at the 18th layer in FIGS. 8A and 8B, the 19th layer in FIGS. 9A and 9B, the 20th layer in FIGS. 10A and 10B, and the 21st layer in FIGS. 11A and 11B. 
     From the optical characteristics of the dichroic mirror, it becomes apparent that depending on a change in layer thickness, the optical characteristic of the higher refractive index layer  3   d  is changed larger than that of the lower refractive index layer  3   c . Further, as the results outputted from the optical monitor  10  shown in FIGS. 8A,  9 A,  10 A and  11 A. In the case where the tuning layer  32  is taken as the 21st higher refractive index layer  3   d , the transmittance becomes the peak value at the ideal thickness in the transmission wavelength band (450 to 550 nm); while in the case where the tuning layer  32  is taken as the 19th high refractive index layer  3   d , the transmittance does not become the peak value at the ideal thickness in the transmission wavelength band (450 to 550 nm). 
     As is apparent from the above-described simulation, it may be desirable that, of the plurality of alternately stacked layers constituting the multi-layer film  30  formed on the optical component, the higher refractive index film  3   d  positioned near the uppermost surface remotest from the base  3   a  be set as the tuning layer  32 . 
     Next, one example of a method of producing an optical component using the optical component producing apparatus will be described with reference to FIGS. 1 to  3 , and FIGS. 12 and 13. 
     In the optical thin layer forming apparatus  1 , the base  3   a  having a thickness of 188 μm, made from polyethylene naphthalate, is set on the feed roll  4  to be wound around the winding roll  6  by way of the guide rolls  5   a ,  5   b ,  5   c ,  5   d ,  5   e , and  5   f.    
     An SiOx (x is a positive number of 2 or less) is formed on the base  3   a  by sputtering the evaporation source  7   a  having an Si target while adjusting a flow rate of each of Ar gas and oxygen gas. Subsequently, 21 optical thin layers made from SiO 2  and Nb 2 O 5  are formed one by one to satisfy a predetermined optically designed configuration by alternately sputtering the evaporation source  7   b  having an Nb target and the evaporation source  7   a  having the Si target while adjusting a flow rate of each of Ar gas and oxygen gas. In addition, the SiOx layer is taken as one of the SiO 2  layers of the above 21 layers. 
     Upon formation of the optical thin layers, to reduce a stress applied to the optical thin layers, the flow rate of each of Ar gas and oxygen gas for sputtering is adjusted by the gas lead valve  9  to change the sputtering pressure. For example, while the usual sputtering pressure is about 0.3 Pa, the sputtering pressure used in this embodiment is set at about 1.6 Pa, to reduce the entire internal stress of the optical thin layers while adjusting the balance in stress between SiO 2  and Nb 2 O 5 , thereby reducing a curling of the film-like base  3   a.    
     With respect to the base  3   a , previously, a hard coat layer is formed on the surface on which optical thin layers are to be formed, and an adhesive layer is formed on the opposed surface to the optical thin layer formation surface and a protective film is formed on the adhesive layer. Since the base  3   a  made from polyethylene naphthalate has a high heat resistance, that is, a high resistance against thermal deformation, optical thin layers can be uniformly formed on the base  3   a . For example, polyethylene naphthalate having a glass transition point of 110° C. is superior in heat resistance to polyethylene terephthalate having a glass transition point of 69° C. 
     A glass plate having a width of 5 cm, a length of 8.75 cm, and a thickness of 1 mm is prepared as a transparent member. The base  3   a , on which the optical thin layers have been formed, is laminated on the transparent member via an adhesive, and is then cut into a size matched to that of the glass plate. In this way, an optical component applicable to a dichroic mirror used for typically a projection television is finished. In addition, a protective film formed on an adhesive layer may be used as the transparent member. 
     As described above, the optical monitor  10  is essential for stably producing an optical component (optical filter) having a high quality. 
     FIG. 12 is a diagram showing one example of simulation of a change in mean transmittance in the case of gradually increasing the thickness of an optical thin layer by using the optical monitor, and FIG. 13 is a diagram showing one example of a difference in final transmittance distribution between an optical component in which the thickness adjustment by using the optical monitor is performed and an optical component in which the thickness adjustment by using the optical monitor is not performed. 
     FIG. 12 shows a change in mean transmittance in the case of changing the thickness of the tuning layer  32  by about ±20 μm in the case where light is made incident on the base in the vertical direction. The ideal thickness of the tuning layer is typically 94.76 nm. The mean transmittance of the tuning layer  32  is increased as the thickness thereof is gradually increased from 74.76 nm, reaching the peak value when the thickness of the layer  32  is increased to about 94.76 nm, and is changed to be decreased as the thickness of the layer  32  is further increased. Further, as shown in FIG. 13, the mean transmittance in a transmission wavelength band (450 to 550 nm) of the optical component in which the thickness adjustment by using the optical monitor  10  is performed is about 7% higher than that of the optical component in which the thickness adjustment by using the optical monitor  10  is not performed. Accordingly, it is possible to produce an optical component having a high quality by using the optical monitor  10 . 
     According to this embodiment, it is possible to easily, stably produce an optical component having a good optical characteristic. 
     While the preferred embodiment has been described using the specific terms, such description is for illustrative purposes only, and it is to be understood that changes and variations may be made without departing from the spirit or scope of the following claims.