Abstract:
A method for manufacturing an optical device provides at least two sub-bodies of a base body and, at each sub-body, a surface so that the surfaces are complementary to each other and snugly fit on one another. Along at least one of the complementary surfaces, a first optical layer system is defined. The sub-bodies are joined along the complementary surfaces so as to embed the optical layer system between them and thus forming an assembled sub-body. Machining a continuous surface on the assembled sub-body and at a predetermined angle to the complementary surfaces and the embedded layer system then takes place, where the latter abut at the machined continuous surface. A second layer system is then provided along the continuous surface.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]    This application is a divisional of application Ser. No. 08/756,140 filed Nov. 26, 1996 and now U.S. Pat. No. ______, which claims priority on Swiss application number 2694/96 filed Nov. 1, 1996. 
     
    
     
       FIELD AND BACKGROUND OF THE INVENTION  
         [0002]    The present invention concerns an optical element that comprises a base body and an optically effective layer system of which at least one layer system surface contacts the base body.  
           [0003]    The invention also comprises a related manufacturing process, the utilization of such a component or process, as well as an optical projection arrangement.  
           [0004]    Introduction:  
           [0005]    German patent reference DE-40 33 842 discloses a cuboid optical element composed of dichroitic layers referred to as a “dichroitic prism.” 
           [0006]    In the present application the term X-cube is used.  
           [0007]    The present invention starts with the problems that exist with known X-cubes, as described, for example, in DE-40 33 842, or that occur in its manufacture. The present invention which was developed in order to find a solution to the problems with such elements, can be applied to a number of other optical elements.  
           [0008]    For this reason this description begins with the specific problems to be solved on X-cubes and based thereon explains the application of the invention in more general terms.  
           [0009]    Description:  
           [0010]    Based on FIG. 1 the basic functional principle of an X-cube is explained. Optical elements of this type are principally used in projectors in order to recombine the red/green and blue channels in the spectral range of the visible light. As shown in FIG. 1 such an X-cube  1  comprises four individual prisms  2   a  to  2   d  which can, for example, be made of BK7 glass. In their cross-section they form right-angled isoceles triangles with an angle of 90 degrees, usually with a tolerance of over ±60 angular seconds, and hypotenuse angles of 45 degrees with tolerances of a few angular minutes. The length of the hypotenuse is typically between 5 mm and 50 mm, preferably 40 mm. Embedded between the two prism pairs  2   a  and  2   b  on the one side,  2   d  and  2   c  on the other side, there is an optically effective layer system  5  that largely reflects visible light in the blue range but largely transmits visible light in the green or red range. FIG. 1 shows a part of the blue reflector layer system as a color splitting system, labeled  5 ′, the other  5 ″.  
           [0011]    Embedded between the two prism pairs  2   a  and  2   d  on the one side,  2   b  and  2   c  on the other side there is an additional, optically effective layer system  7 , that largely reflects light in the red range but largely transmits light in the green range and the blue range. In FIG. 1 also the two legs of the red reflector layer system are shown as a color splitter system, labeled  7 ′ and  7 ″.  
           [0012]    On the X-cube there are three input channels for red, green and blue light from corresponding sources, for example, LCD controlled, and an output channel with the recombined input signals. On the reflector systems, between each of said prism pairs, the correspondingly colored light, and particularly S-polarized light with an incidence angle of less than 45 degrees is reflected. In addition the hypotenuse surfaces of the prisms  2  can be and usually are coated with an antireflection layer system.  
           [0013]    Because the pixels of the red-blue-green input channels should converge as accurately as possible, the angle tolerances on prism  2  and in the assembled X-cube must be very narrow.  
           [0014]    Large tolerances result in poor imaging quality because the pictures do not accurately converge: blurring or color fringes occur.  
           [0015]    Location  9 , shown with dashes in FIG. 1 where the four individual prisms  2  meet, is also located within the imaging optical path. Optical interferences created in this location manifest themselves, as mentioned for example, as a blurred picture in the output channel OUT. It is a requirement of such elements and their manufacturing process to minimize the interferences, particularly in this location  9 .  
           [0016]    From DE-40 33 842, for example, it is known that X-cubes can be manufactured from four prisms  2  according to FIG. 1. The four individual prisms are first manufactured in their exact dimensions through milling, grinding and polishing. Subsequently they are coated with the appropriate layer system along their leg and possibly on their hypotenuse surfaces with an antireflection coating. Finally the coated individual prisms  2  are cemented together.  
           [0017]    Disadvantages of the Known Processes and Known X-Cubes:  
           [0018]    The handling effort required for manufacturing the X-cubes as described, for example, in DE-40 33 842, is very high: First, each of the three lateral sides of each individual prism  2  must be mounted or fixed by plastering, blocking or wringing as shown in FIG. 1 before the glass can be worked. Subsequently the surfaces must be cleaned for coating the individual prisms  2 , and then mounted and dismounted for the coating process. On an average two sides per individual prism need to be coated. This laborious handling considerably raises the production costs for such X-cubes.  
           [0019]    From FIG. 1, particularly location  9 , it is evident that the coating of the red and blue reflecting layer systems must be executed in such a way that the coating does not wrap around the 90 degree edges of the individual prisms. This requires sophisticated coating fixtures or masking of the legs on which no coating may be deposited. In this respect we refer U.S. Pat. No. 2,737,076 (Rock et al.).  
           [0020]    During the coating and the handling of the individual prisms  2 , the 90 degree prism edges are exposed without protection, that is, especially those edges which according to the foregoing explanation must be very accurate. This inevitably leads to chipping unless laborious precautions to protect these edges are taken, which again increases the costs.  
           [0021]    If, for example, anything goes wrong during the coating of the individual prisms  2 , such an individual piece must be remounted, ground, and repolished, otherwise it will have to be discarded. Correction processes are at best very difficult to implement.  
           [0022]    Cementing of the individual prisms  2  in the exact relative position is very difficult and laborious. Complicated processes such as described in DE-40 33 842 are required. Prisms are cemented individually which is time-consuming and therefore costly.  
           [0023]    Independently of said disadvantages the known process results in a structure in location  9  as shown in FIG. 1, as can be seen from the detail in FIG. 2. The same reference marks are used as in FIG. 1 are used. Item number  11  identifies the cemented joints.  
           [0024]    From this it is evident that the cemented joints  11  cause an interruption of the red light reflection layer system  7  (consisting of  7 ′ and  7 ″) as well as the blue light reflection layer system  5  (consisting of  5 ′ and  5 ″).  
           [0025]    As the X-cube is manufactured by cementing the individual prisms  2  whose 90 degree edges have been exposed to external influences without protection, faults occur almost inevitably in location  9  due to chipping defects along the 90 degree edges of the individual prisms.  
         SUMMARY OF THE INVENTION  
         [0026]    The purpose of the present invention is to propose an optical element, in particular an X-cube, which is not afflicted by the disadvantages explained on the basis of FIG. 2.  
           [0027]    It is also the objective of the present invention to propose a manufacturing process that is not afflicted by said disadvantages in production, in particular of said X-cubes. The manufacturing process to be found should by highly economical, afford greater accuracy, and require fewer process steps.  
           [0028]    In an optical element of the type referred to at the beginning, this is achieved by deposition on the body, a second layer system that adjoins the surface of the first layer system at an angle. In this way the first mentioned, optically effective layer system is areally continuous and the second layer system adjoins one of the surfaces of the first one without a gap. A structure as has been explained based on FIG. 2 is avoided: According to the invention, with reference to FIG. 2, one of the layer systems, preferably  7 , is continuous; individual sections  7 ′,  7 ″ no longer exist. According to the invention a second layer system, preferably system  5 ,  5 ′ adjoins that continuous layer system  7 , and in the case of an X-cube also a third layer system,  5 ″. The is not illustrated in FIG. 2 which shows the familiar intersection structures.  
           [0029]    Characteristic for the process according to the invention is that for solving the aforementioned task one surface each is created on at least two sub-bodies of the base body of the element, where said two surfaces are complementary to each other on at least two sub-bodies, that is, they fit together with close tolerances. Subsequently at least one of these complementary surfaces is coated with an optically effective layer system, in particular the red or blue reflection layer system, if the element to be produced is an X-cube.  
           [0030]    Subsequently, said sub-bodies are joined, for example, by cementing along said complementary surfaces with their now embedded layer system. A composite sub-body is thus formed. On the composite sub-body one surface that is common to at least two sub-bodies is processed which is at an angle to the complementary, interconnected surfaces, so that the complementary surfaces along which the sub-bodies are connected intersect the common surface to be processed. Finally another optically effective layer system is deposited along this jointly processed surface.  
           [0031]    The preferred design versions of the element or process according to the invention are specified in the dependent claims. The element according to the invention is preferably used as an X-cube, or the process according to the invention is preferably used for manufacturing such X-cubes.  
           [0032]    An optical projection arrangement with at least one element designed as an X-cube according to this invention has significantly reduced optical interference, especially in the center area  9  shown in FIG. 2, and due to the proposed production process it can be manufactured more economically and more accurately. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0033]    The invention is subsequently explained by means of the following illustrations:  
         [0034]    [0034]FIG. 1 is a top view of an X-cube of the conventional type for explaining the functional principle;  
         [0035]    [0035]FIG. 2 is a central intersection area of the optically effective layer system on a conventional X-cube according to FIG. 1;  
         [0036]    [0036]FIG. 3 is a perspective view of an intermediate product resulting from the process according to the invention, a product that is already an optical element according to the invention;  
         [0037]    [0037]FIGS. 4 a  to  4   h  are intermediate products resulting from the process according to the invention, where the structures according to FIGS. 4 f,    4   g  and  4   h  already represent an optical element according to the invention;  
         [0038]    [0038]FIG. 5 is an enlarged view showing the intersection area of the layer system on the intermediate product according to the invention as shown in FIG. 4 f;    
         [0039]    [0039]FIGS. 6 and 7 are generalized optical element structures according to the invention with their layer system intersection areas;  
         [0040]    [0040]FIG. 8 is an enhanced development of the optical element illustrated in FIG. 5, or its intersection area according to the invention;  
         [0041]    [0041]FIG. 9 is a view like FIG. 8 but based on the intersection area shown in FIG. 5, showing an enhanced development of an element according to the invention;  
         [0042]    [0042]FIG. 10 shows a central intersection area on an optical element according to the invention, particularly as manufactured by the production process according to the invention, in comparison with the traditional intersection area shown in FIG. 2 on traditional optical components of the X-cube type; and  
         [0043]    [0043]FIG. 11 is a schematic representation of a generalized optical element according to the invention as can be realized with the aid of the present invention. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0044]    With respect to the production process of an X-cube according to the invention, FIG. 3 shows already an intermediate product according to the invention; it is the cuboid product from four sub-cubes  20   a  to  20   d.  Between the sub-cube pairs  20   a  and  20   d  on the one side and  20   b  and  20   c  on the other, there is a first optically effective layer system—for X-cube production and analogously to FIG. 1 layer system  7 —whereas between the cube pairs  20   a  and  20   b  or  20   d,    20   c  there is another optically effective layer system, that is, in the X-cube production and with respect to FIG. 1 layer system  5  with the parts  5 ′ and  5 ″. For the production of the X-cube length  1  of cube  22  is 1 to 8 X-cube lengths or greater, in particular 4 X-cube lengths, in FIG. 1 measured perpendicularly to the plane of the illustration. Basically this product whose manufacturing steps will subsequently be explained, is characterized as follows:  
         [0045]    All existing angles are 90 degrees (± tolerances), which means that the sub-bodies  20  and the intermediate product  22  are easy to manufacture, because among others, the opposite sides can be machined at the same time such as by dual lapping or dual polishing.  
         [0046]    In simultaneous double-sided machining high parallelisms of the mutually opposite surfaces can be achieved, for example, with deviations of ≦2 μm across a length of 150 mm. In addition a high planarity of each surface is achieved, for example, with planarity deviations of ≦1 μm across lengths of 150 mm.  
         [0047]    Because all angles involved are 90 degrees (± tolerances), each of the parts  20   a  to  20   d  and  22  can be easily mounted and positioned. In dual lapping or dual polishing operations no elaborate fixture is required and the corresponding part can simply be inserted into a polishing insert. Mounting of the parts by plastering, blocking or wringing can preferably be eliminated.  
         [0048]    All angles involved can be manufactured with high precision because they are all 90 degree angles and no angles of 45 degrees, for example, that are much more difficult to produce. The angle tolerances for the 90 degree central angle of the sub-bodies  20  are preferably no greater than ±20 angular seconds.  
         [0049]    The measurement instrumentation for geometrically measuring the produced parts can be kept very small by using an interferometer, for example.  
         [0050]    Particularly when plan parallel complementary surfaces to be cemented are used, cementing is very easy and cemented joints of accurately defined thickness can be produced.  
         [0051]    The production of such parts is easy to scale, that is, by using plates of various sizes several workpieces  22  referred to as T-cubes can be produced in a single piece that is subsequently singularized.  
         [0052]    Optical measuring on coated surfaces of cuboid bodies with plan parallel surfaces is much simpler than on triangular prisms.  
         [0053]    The following step-by-step description based on FIGS. 4 a  to  4   c  describes the manufacturing of body  22  shown in FIG. 3 which is already a product of the invention, is manufactured. It will become obvious that the disadvantages in the central area  9  as discussed on the basis of FIG. 2 are actually eliminated with respect to layer arrangement and edge precision.  
         [0054]    [0054]FIG. 4 a  shows a plate for blanks  20 ′.  
         [0055]    Through dual lapping, mutually opposite surfaces are machined according to FIG. 4 b,  particular the surfaces ∇∇.  
         [0056]    Subsequently one of the surfaces ∇∇ of plate  20 ′ is coated with a layer system  5 ′ according to FIG. 4 b,  resulting in plate  20 ″.  
         [0057]    If the manufacturing process described here involves the production of X-cubes, preferably and as shown in FIG. 4 b  the blue reflection system  5 ′ is deposited because the blue image may have more blur than the red image due to the corresponding sensitivity of the human eye.  
         [0058]    It should be noted here that the plate  20 ′ corresponds to the dimension of one or several elements, preferably four, in direction y as well as direction x; a singularization in both dimensions will be performed later.  
         [0059]    According to FIG. 4 c  plates  20 ′ and  20 ″ are laminated, preferably by cementing, in such a way that the aforementioned layer system, preferably the blue reflection system  5 ′, is embedded between them.  
         [0060]    Whether only the surface of one of the plates  20 ″ involved is coated or both, and correspondingly the cement film is located between the surface of one plate  20 ′ and the layer, or between two layers, depends on the intended application. Preferred in the production of X-cubes is the coating of one of the complementary surfaces involved, and cementing of this surface with the complementary surface of the uncoated plate  20 ″.  
         [0061]    The term complementary surfaces is used because, as will be shown later for other applications, the bodies with surfaces of any curvature can be placed on top of each other with the embedded layer system, provided the surfaces involved are complementary with the required accuracy.  
         [0062]    As shown in FIG. 4 d  the dual plates  20 ′ and  20 ″ are singularized by sawing them into bars  24 .  
         [0063]    As shown in FIG. 4 e  the sawed bars  24  are tilted by 90 degrees and preferably two or more such bars are placed adjacent to each other,  26 , or as shown in the diagram on the left, an individual bar  24  is further processed.  
         [0064]    For forming the plate  26  the bars must be aligned in such a way that in the next processing step the second layer system which in the X-cube production is the red reflection system  7 , is deposited exactly perpendicular on the surface to be processed. This is greatly simplified by the fact that all surfaces of the bar or bars  24  are perpendicular and practically plan parallel to each other and because they are extremely flat. For example, as indicated at  25 , preferably several bars  24  can be wrought together in order to compensate any angular error resulting from the sawing process. As mentioned and as shown on the left, also individual bars  24  can be lapped or polished if the sawing process is sufficiently accurate. Lapping and polishing are given as examples of joint mechanical machining.  
         [0065]    As shown with ∇∇∇ the opposite lateral surface of plate  26  or of the individual bar  24  can now be dual lapped or dual polished.  
         [0066]    As shown in FIG. 4 f  and as a very important step of this invention, one of the polished surfaces of the plate  26  or the individual bar  24 , in the first case for all bars  24  involved, are jointly repolished and subsequently coated. In the X-cube production a red reflection layer system  7  is deposited at this point, as shown in FIG. 4 f.    
         [0067]    In this way the first layer system  5  and the cementing film are full-surface coated with  7  after repolishing. Preferably a relatively cold coating process is used, preferably a plasma and/or ion assisted coating process, preferably a sufficiently cold PVD process, preferably sputtering, or PECVD process, but in particular a cold coating process with substrate temperatures not exceeding 150 degrees C., preferably not exceeding 80 degrees C.  
         [0068]    The structure of the process according to FIG. 4 f  and the procedure proposed so far are inherently inventive, regardless of whether or not the layer systems represented with  5 ′ and  7 ′ are deposited perpendicularly or obliquely to each other, and whether or not the coated surfaces are plane or as mentioned above, complementary curved. Intersections  9 ′ are created on which one layer system— 7 —continuously overlaps the intersection of the second layer system— 5 —.  
         [0069]    According to FIG. 4 g  an uncoated plate  26  or an uncoated individual bar  24 , after unwringing if applicable, and a coated plate  26 ′ or a coated individual bar  24 ′ are placed on top of each other and cemented as shown in FIG. 4 f.  The layer system  5 ′ of the uncoated plate  26  or the uncoated bar  24 , as the third deposited layer system in addition to the two systems  7  and  5 ′ on the coated plate  26 ′ or the coated bar  24 ′, now becomes layer system  5 ″.  
         [0070]    The resulting T-cube strips  28  are singularized into the desired lengths  1 . But before singularization for the production of the X-cube the T-cubes are preferably chamfered by sawing and by machining their surfaces along planes E, preferably again on two sides, as shown with E 1 , E 2 , and E 3 , E 4  respectively. After cutting to size in direction  1 , very accurate X-cubes  1 ′ according to the invention are obtained. The 45 degree angle tolerances do not exceed ±2 angular minutes, preferably no more than ±1 angular minute. If applicable the chamfered surfaces corresponding to planes E in FIG. 4 h  are coated with an antireflection system before the X-cubes are singularized.  
         [0071]    Looking back at FIG. 4 f,  FIG. 5 is a detail  9 ′ of an optical element  1  according to the invention, as it occurs in the production of X-cubes. In the latter a first optical layer system corresponding to  5 ′ made of glass or plastic, preferably BK7 glass or polycarbonate or PMMA, which in X-cube production is the blue reflection system, is located between the plan parallel surfaces of the two separated bodies  20 ′,  20 ″ (FIG. 4 e,    4   d ). The two bodies  20 ′,  20 ″ are cemented at  11 ′. After joint surface finishing by polishing or lapping, layer system  5 ′ covered with cement film  11 ′, the second optical layer system corresponding to  7 , in the case of the X-cube a red reflection system, is deposited on both bodies  20 ′ and  20 ′″. As can be seen from the comparison with FIG. 2, the bisectioning of  7  into  7 ′ and  7 ″ is eliminated through this invention.  
         [0072]    Through this process the intersection area normally exhibits only a slight indentation of the cement film  11 ′ as shown at  30  in FIG. 5, which has a maximum depth d with respect to the plane surface of layer  7  of max. 5 μm, preferably max. 2 μm.  
         [0073]    [0073]FIG. 6 shows in a generalized concept of FIG. 5 an optical element according to the invention in which the second layer system  5 ′ a  intersects obliquely with the plane layer system  7   a.    
         [0074]    In FIG. 7 the complementary surfaces of the bodies  20 ′ b′,    20 ″ b  are curved, the same applies to the common surface coated with layer system  7   b.  In a highly defined manner layers  5 ′ and  7 ′ intersect according to FIG. 5, for X-cube production in particular at a right angle. The one layer system— 7 —is continuous and in particular runs also across the point of intersection. This is particularly important in all applications where the intersection areas, for example corresponding to  9 ′ b  in FIG. 7 or  9 ′ a  or  9 ′ in X-cube production, have an effect on the optical path of the light influenced by the layer systems, in particular the visible light. The professional now readily recognizes, particularly in conjunction with FIG. 4, how analogously optical elements can also be manufactured according to FIGS. 6 and 7, optical elements which according to current knowledge have probably never been realized. This results in completely new component structures that are suitable for optical beams in the visible range as well as the non-visible spectral range such as UV or IR.  
         [0075]    [0075]FIG. 8 shows the structure of another element according to the invention in which, based on the one in FIG. 5 and analogously to FIGS. 6 and 7, the continuous layer system  7  or  7   a  or  7   b  is covered by an additional body  24 ″ and a cement film.  
         [0076]    [0076]FIG. 9 shows the intersection area on the element according to the invention, for example, as shown in FIG. 5, in which the layer system  7  or with respect to FIG. 7, 7 a  or  7   b  is additionally coated, for example with a protection layer system  40 .  
         [0077]    Finally FIG. 10 shows the intersection area resulting in the production of a structure according to FIG. 3, that is, particularly an X-cube, where the continuous layer system  7  is preferably designed as a red reflection system. An analogous element indicated with the reference marks ‘a’ or ‘b’ is obtained based on FIG. 6 or  7 .  
         [0078]    [0078]FIG. 11 shows such a generalized optical element  42  according to the invention; the professional readily recognizes the multitude of possibilities that are opened by this invention.  
         [0079]    In particular in the X-cube production with 90 degree blanks the more accurate machinability of mutually opposed surfaces, the cementing of the blanks, the joint coating and surface finishing and, preferably, the singularization into individual optical elements as the last step affords a considerable reduction of the manufacturing costs. It also results in elements with significantly fewer optically effective fault locations when we take into consideration that in the proposed process the delicate, centrally located 90 degree edges are never exposed.  
         [0080]    Dielectric layer systems with at least one dielectric layer are preferably used as optically effective layer systems, particularly in the production of X-cubes. Suitable coating processes are the aforementioned, sufficiently cold processes. Of course, elements can be manufactured that are effective in spectral ranges other than visible light, for example in the UV or IR range, and in addition to color splitting layer systems, also reflection layer systems, antireflection layer systems, or polarization layer system can be used or integrated. In particular X-cubes used in projection systems can be manufactured for which high-precision, low-cost optical elements are required.