JP5939560B2 - Reflector array optical device and manufacturing method thereof - Google Patents

Description

  The present invention relates to an optical device that forms a real image (real mirror image) of an object to be observed in a space on an observer side and a method for manufacturing the same.

  There has been proposed a display device in which a real image (real mirror image) of an object to be observed is formed in the air so that an observer can see it (see Patent Document 1).

  Such a display device has a real mirror image imaging optical system that forms a real image (real mirror image) of an object to be observed in a space on the viewer side, and is opposite to the observer side of the real mirror image imaging optical system. And an object to be observed for forming the real image (real mirror image) disposed in the side space. Such a real mirror image forming optical system can form a real image (real mirror image) of an object to be observed at a symmetrical position with respect to a symmetry plane of the real mirror image forming optical system.

  Patent Document 1 discloses a plane of a plurality of unit optical elements (each referred to as a two-surface corner reflector) each composed of two minute mirror surfaces (reflection surfaces) orthogonal to each other as an actual mirror image forming optical system or optical element. Suggests a collective assembly. Patent Document 1 discloses a two-sided corner reflector array optical element in which a plurality of two-sided corner reflectors are arranged in an array on a single plane, that is, in a grid pattern. The two-sided corner reflector array optical element is a two-sided corner reflector that uses the inner wall of an optical through hole that is assumed to penetrate the element surface as a mirror surface, or a transparent surface that protrudes from the surface of the transparent substrate. Some use the inner wall of the cylindrical body as a mirror surface. In addition, since the transparent cylindrical body is a prism or prism in which an optical hole protrudes in a cylindrical shape and the inside is filled with a light-transmitting material, the transparent cylindrical body is hereinafter simply referred to as a protruding portion. To do.

  In the two-surface corner reflector array optical element, each mirror surface of the plurality of aligned two-surface corner reflectors is arranged upright substantially perpendicular to the element surface, and therefore, from the object to be observed arranged on one side of the element surface. When the light beam passes through the element surface, it is reflected twice by the two-surface corner reflector, and the light beam is bent and passes through the element surface, and the space on the other principal surface side of the element surface without the object to be observed. To form a real image. That is, the two-surface corner reflector array optical element can form a real image so that the object to be observed exists at a symmetrical position with respect to the element surface (also referred to as a symmetry plane) of the two-surface corner reflector array optical element. it can.

International Publication No. 2007-116639

  The two-surface corner reflector optical element having an inner wall of an optical through hole described in Patent Document 1 as a mirror surface is manufactured using an electroforming method. In addition, the two-surface corner reflector optical element that uses the inner wall of the protruding portion as a mirror surface is manufactured using a resin molding method by manufacturing a mold. In any of the manufacturing methods, it is necessary to precisely process the mold, and it is very difficult to manufacture a large-area two-sided corner reflector optical element, and a plate-like optical element having a size of 10 cm □ at most is used. The limit is to produce.

  Accordingly, an object of the present invention is to provide a reflector array optical apparatus which is a large real mirror image forming optical system using a dihedral corner reflector array optical element, and a manufacturing method thereof.

  According to the present invention, a reflector array optical device for forming a real image of an object to be observed on one main surface side in a space on the other main surface side includes a plurality of two-surface corner reflector array optical elements juxtaposed on the same plane. Have Each of the plurality of two-surface corner reflector array optical elements has a base, and at least two orthogonal side surfaces that are perpendicular to the main surface of the base and orthogonal to each other, and the directions of the internal angles of the orthogonal side surfaces are aligned. And a plurality of two-surface corner reflectors integrally formed on the base. In the reflector array optical device, the plurality of two-surface corner reflector array optical elements may be arranged such that the intersecting line of the orthogonal side surfaces of the plurality of two-surface corner reflectors is parallel to the normal of the substrate. It is characterized by being bonded together. That is, the reflector array optical device of the present invention is a large-area two-surface corner reflector optical element assembly composed of a plurality of tiling (planar filling) two-surface corner reflector optical elements.

  In the reflector array optical device of the present invention, adjacent ones of the plurality of two-surface corner reflector array optical elements are arranged so that the directions of the inner angles of the orthogonal side surfaces of the plurality of two-surface corner reflectors are aligned. May be.

  In the reflector array optical device of the present invention, the plurality of two-surface corner reflectors are arranged in a matrix at the same pitch, and adjacent ones of the plurality of two-surface corner reflector array optical elements are the plurality of the plurality of two-surface corner reflector array optical elements. You may arrange | position so that the said orthogonal side surfaces of a 2 surface corner reflector may align in parallel.

  In the reflector array optical device of the present invention, each of the plurality of two-sided corner reflector array optical elements is made of a transparent material, and each of the plurality of two-sided corner reflectors has a prism shape protruding from the base. Part.

  In the reflector array optical device of the present invention, the prismatic shape has a side surface inclined from the normal line of the base on the side facing the intersecting line of the orthogonal side surfaces, and a bottom surface integrated with the base and the bottom surface A truncated pyramid shape having an upper surface with an area smaller than the area can be included. That is, each of the two-surface corner reflector array optical elements has a plurality of truncated pyramids projecting from the surface of the substrate integrally formed from a transparent material, and two orthogonal surfaces of the four side surfaces of the respective truncated pyramids. Is formed as a plane perpendicular to the base (two-sided corner reflector), and the plane other than the two planes is a plane (top) opposite to the base from the plane (bottom) on the base side of the truncated pyramid. It has a structure formed as a flat surface with an inclination that becomes smaller. In this reflector array optical device, it is preferable that the inclination angle of the side surface inclined from the normal line of the substrate is 5 degrees or more and 25 degrees or less. If this inclination angle is 5 degrees or more, it functions as a so-called “drawer taper”, so that the two-sided corner reflector optical element molded product can be easily removed from the mold. Considering the removal of the two-surface corner reflector array optical element from the stamper, it is better that this inclination angle is large, but if it is too large, the area of the upper surface of the truncated pyramid that is the light exit surface reflected by the two-surface corner reflector is large. As the image becomes smaller, the real image (real mirror image) of the object to be observed becomes dark. In addition, when the upper surface area is secured, the area of the bottom surface of the truncated pyramid is increased and the number of two-surface corner reflectors per unit area is reduced, so that a real image (real mirror image) of the object to be observed is also obtained. It will be dark. As a result of molding experiments using stampers with various inclination angles for these contradictory phenomena, it is preferable that the inclination angle is 5 degrees or more and 25 degrees or less. In the truncated pyramid, there are two side surfaces (excluding the top surface and the bottom surface) other than the two surfaces forming the two-surface corner reflector, and the both surfaces are inclined as described above. It may or may not be equal. The dihedral corner reflector array optical element is preferably produced by a resin molding method.

  In the reflector array optical device of the present invention, each of the plurality of two-sided corner reflectors can be formed as a prismatic hole penetrating the base having a part of the inner wall as a mirror surface as the orthogonal side surface.

  In the reflector array optical device of the present invention, the base may have an end surface parallel to one side surface of the orthogonal side surfaces.

  In the reflector array optical device of the present invention, the base may have a flat end surface that intersects one of the orthogonal side surfaces at an angle of more than zero and less than 45 degrees.

  In the reflector array optical device of the present invention, the base may have a flat end surface that intersects one side surface of the orthogonal side surfaces at an angle of 45 degrees.

  In the reflector array optical device of the present invention, the end face of the base is polished into a mirror shape.

  In the reflector array optical device of the present invention, the optical adhesive is filled only between the end faces of the base.

  In the reflector array optical device of the present invention, the reflector array optical device may have a transparent flat plate superimposed on the main surface of the base on the opposite side of the plurality of two-sided corner reflectors.

  According to the present invention, there is provided a method of manufacturing a reflector array optical device that forms a real image of an object to be observed on one main surface side in a space on the other main surface side, and a substrate, each of which is perpendicular to the main surface of the substrate and A two-surface corner reflector array optical element comprising a plurality of two-surface corner reflectors integrally formed on the base so as to have at least two orthogonal side surfaces orthogonal to each other and the orientations of the inner angles of the orthogonal side surfaces are aligned. A step of forming at least two sheets, and a masking material for the plurality of two-surface corner reflectors of a main surface portion of the substrate adjacent to an end surface of the substrate to be bonded to each of the two two-surface corner reflector array optical elements. A step of coating and supplying an optical adhesive between the end faces of the bases to be bonded, and part of the optical adhesive is masked from between the end faces of the bases. Bonding the two two-sided corner reflector array optical elements while extruding to the surface of the substrate, and removing the masking material together with a part of the optical adhesive from the plurality of two-sided corner reflectors on the main surface of the base It is characterized by including these. The masking material prevents the optical adhesive from entering a portion where a plurality of protruding portions (two-surface corner reflectors) are arranged. If the optical adhesive remains between the plurality of protrusions, the condition for reflecting the light propagating inside the protrusions after fabrication on the surface of the protrusions changes, so the masking material and the masking material later Removing this has the effect of preventing such a change in reflection conditions.

  In the method of manufacturing a reflector array optical device according to the present invention, the bonding step should be performed by bonding the two two-sided corner reflector array optical elements before supplying the optical adhesive between the end faces of the base. Including the step of bringing the end faces of the bases into contact with each other and attaching and bonding an adhesive tape to the main surface portion of the base in a positional relationship spanning between the end faces of the bonded bases. Before bonding the optical elements, the end surfaces of the adjacent bases are opened with the portion connected by the adhesive tape as a fulcrum (rotation center), and the optical adhesive is supplied between the end surfaces. Then, the end surfaces of the base can be closed and bonded together. It is preferable that the dihedral corner reflector portion of the dihedral corner reflector optical element is formed up to the vicinity of the end face of the element because the seam becomes inconspicuous.

  In the method of manufacturing a reflector array optical device according to the present invention, the bonding step may be performed by supplying the two two-sided corner reflector arrays on the same plane of a flat plate before supplying an optical adhesive between the end faces of the base. The optical elements are arranged so that the end surfaces of the bases to be bonded face each other, and the optical adhesive is supplied between the end surfaces of the bases to be bonded, and then the end surfaces of the bases are It is possible to abut each other toward each other.

  In the manufacturing method of the reflector array optical device of the present invention, the bonding step includes supplying an optical adhesive on the same plane of the transparent flat plate, and the two sheets on the transparent flat plate supplied with the optical adhesive. The two-surface corner reflector array optical elements are arranged so that the end surfaces of the bases to be bonded face each other, and the optical adhesive is supplied between the end surfaces of the bases to be bonded. The two end surfaces of the two-sided corner reflector array optical element can be bonded together by abutting the end faces of each other toward each other.

  According to the bonding step using the adhesive tape, the flat plate, or the transparent flat plate, the main surfaces on the opposite side to the protruding portion side of the bases of adjacent two-sided corner reflector optical elements are aligned (a step is generated. Can be attached in a positional relationship. When a step is generated on the main surface of the adjacent base, distortion occurs in the real mirror image at the bonded portion. However, according to the bonding step, such real mirror image distortion can be prevented.

  In the method for manufacturing a reflector array optical device according to the present invention, the masking material is made of a water-soluble masking material. In the method for manufacturing the reflector array optical device of the present invention, ultrasonic cleaning in water is performed in the step of removing the masking material. Ultrasonic cleaning is excellent and suitable for removing the masking material.

  According to the reflector array optical apparatus of the present invention, it is possible to realize a large real mirror image forming optical system that forms a bright real image (real mirror image) of an object to be observed in a space on the viewer side.

It is a schematic perspective view which shows notionally the structural example of the reflector array optical apparatus of the Example of this invention. It is a schematic perspective view explaining operation | movement of the reflector array optical apparatus of FIG. It is a general | schematic fragmentary top view which shows typically the 2 surface corner reflector array optical element of the reflector array optical apparatus of the Example of this invention. FIG. 4 is a schematic partially cutaway perspective view schematically showing a two-surface corner reflector of the two-surface corner reflector array optical element of FIG. 3. It is a general | schematic fragmentary top view which shows typically the 2 surface corner reflector array optical element of the reflector array optical apparatus of the further Example of this invention. FIG. 6 is a schematic partially cutaway perspective view schematically showing a two-surface corner reflector of the two-surface corner reflector array optical element of FIG. 5. It is a general | schematic fragmentary top view which shows typically the 2 surface corner reflector array optical element of the reflector array optical apparatus of the further Example of this invention. FIG. 8 is a schematic partially cutaway perspective view schematically showing a two-surface corner reflector of the two-surface corner reflector array optical element of FIG. 7. It is sectional drawing (a) in the AA cross section of FIG. 8, and sectional drawing (b) in the BB cross section. It is a perspective view which shows typically the truncated pyramid of the 2 surface corner reflector array optical element concerning the Example of this invention. It is a top view which shows notionally the 2 surface corner reflector array optical element molded article for the 2 surface corner reflector array optical element of the reflector array optical apparatus of the Example of this invention. FIG. 12 is a schematic plan view conceptually showing a two-surface corner reflector array optical element cut out from the two-surface corner reflector array optical element molded product of FIG. 11. It is a top view which shows notionally the 2 surface corner reflector array optical element molded article for the 2 surface corner reflector array optical element of the reflector array optical apparatus of the Example of this invention. It is a schematic plan view which shows notionally the 2 surface corner reflector array optical element cut out from the 2 surface corner reflector array optical element molded article of FIG. It is a schematic plan view which shows notionally the 2 surface corner reflector array optical element of the other Example of this invention. It is a perspective view which shows typically the 2 surface corner reflector array optical element for demonstrating the procedure of the process of bonding the two 2 surface corner reflector array optical elements in the 1st reflector array optical device manufacturing method of this invention. . It is a schematic perspective view which shows notionally the reflector array optical apparatus which bonded together the four 2 surface corner reflector array optical elements concerning the Example of this invention. It is a perspective view which shows typically the 2 surface corner reflector array optical element for demonstrating the procedure of the process of bonding the two 2 surface corner reflector array optical elements in the 2nd reflector array optical device manufacturing method of this invention. . It is a perspective view which shows typically the 2 surface corner reflector array optical element for demonstrating the procedure of the process of bonding the two 2 surface corner reflector array optical elements in the 3rd reflector array optical device manufacturing method of this invention. . It is a schematic perspective view which shows notionally the reflector array optical apparatus which bonded together the four 2 surface corner reflector array optical elements concerning the other Example of this invention. It is a schematic perspective view which shows notionally the reflector array optical apparatus which bonded together the four 2 surface corner reflector array optical elements concerning the other Example of this invention. It is a microscope picture of the reflector array optical apparatus of the Example of this invention.

  Hereinafter, a reflector array optical apparatus according to an embodiment of the present invention will be described with reference to the drawings.

  FIG. 1 is a perspective view schematically showing the configuration of the reflector array optical device 3 of the embodiment. In this reflector array optical device 3, the same two-surface corner reflector array optical elements 6, 7, 8, and 9 (four small panels) are arranged in parallel on one plane and their end faces are joined together. The whole is configured as one large panel. Further, each of the four two-sided corner reflector array optical elements 6, 7, 8, and 9 is arranged in parallel so that a plurality of two-sided corner reflectors 61 exist on the same plane. Each of the two-surface corner reflector 61 is composed of two mutually orthogonal mirror surfaces 61a and 61b. A large number of two-surface corner reflectors 61 are arranged in an array, that is, in a grid pattern. The two-surface corner reflector array optical elements 6, 7, 8, and 9 are bonded to form a collective array region of the plurality of two-surface corner reflectors 61. As shown in FIG. 1, four double-sided corner reflector array optical elements 6, 7, 8, and 9 have all the double-sided corner reflector arrays in which the intersection line CL of the mirror surfaces 61a and 61b of all the double-sided corner reflectors 61 is all. The end faces 60a of the bases of the two-surface corner reflector array optical elements 6, 7, 8, 9 are bonded to each other so as to be parallel to the normal line of the main surface of the optical element.

  As shown in FIG. 2, the reflector array optical device 3 has a real image 5 (real mirror image) of the observation object in a space on the other side of the device when the observation object 4 is arranged on one main surface side. Make an image. That is, the reflector array optical device 3 can form the real mirror image 5 of the object 4 to be observed at a plane-symmetric position with the element surface 6S as a symmetry plane. The element surface 6S of the reflector array optical device 3 is a virtual plane that is substantially perpendicular to the two mirror surfaces 61a and 61b that constitute the two-surface corner reflector 61, respectively. Since the two-surface corner reflector 61 is very small (μm order) compared to the overall size (several tens of centimeters to several meters) of the reflector array optical apparatus 3, the two-surface corner is shown in FIGS. The entire set of reflectors 61 is represented in gray, and the direction of the inner corner is conceptually represented in a V shape.

  FIG. 3 is a partial plan view specifically showing a part of a dihedral corner reflector array optical element of one example of four small panels. The two-sided corner reflector array optical element 6 includes a plurality of rectangular parallelepiped protrusions 40 arranged in a grid pattern and a base 60 that holds the protrusions, and the protrusions 40 and the base 60 are made of a transparent material. It is molded and configured. On the surface of the dihedral corner reflector array optical element 6, a plurality of rectangular parallelepiped protrusions 40 each having the same prismatic shape are arranged and arranged. The back surface of the dihedral corner reflector array optical element 6 is a flat surface.

  FIG. 4 shows a perspective view of a part of the two-surface corner reflector array optical element 6 of FIG. 3 (4 × 4 cuboid protrusion 40). The four side surfaces of the protruding protrusion 40 are perpendicular to the main surface of the base 60. The inner wall surfaces 61 a and 61 b of two adjacent orthogonal side surfaces of each of the rectangular parallelepiped protrusions 40 are the two-surface corner reflector 61. Light rays that enter from the base 60 side and travel toward the inner wall surfaces 61a and 61b of the cuboid protrusion 40 are reflected twice by the inner wall surfaces 61a and 61b (mirror surfaces) and are emitted from the upper surface of the cuboid protrusion 40.

  As a method for producing a two-sided corner reflector optical element, there are an injection molding method and a hot press molding method of a resin such as acrylic using a mold. A mold such as a stamper can be manufactured by electroforming reversal after forming a shape corresponding to the protruding portion (cuboid, cube) on a metal master plate by nano-processing. As another method for manufacturing the two-surface corner reflector optical element, for example, by using a direct X-ray lithography method or the like, a plurality of rectangular parallelepipeds and cubes having four-surface vertical sidewalls can be directly manufactured on the transparent resin substrate. .

  Further, as the two-sided corner reflector 61, the inner wall of the cube-shaped through hole 50 penetrating the base can be used in addition to the inner wall of the protruding portion of the transparent rectangular parallelepiped protruding from the surface of the transparent base as a mirror surface. .

  FIG. 5 shows a plan view of a part of one two-sided corner reflector array optical element 6 of a small panel that can constitute the reflector array optical apparatus of another embodiment. The surface of the dihedral corner reflector array optical element 6 is provided with a plurality of cube-shaped through holes 50 that are identical to each other. FIG. 6 is a perspective view of a part (4 × 4 cube-shaped through hole 50) of the two-surface corner reflector array optical element 6 of FIG. Four inner side surfaces of the cube-shaped through hole 50 are perpendicular to the main surface of the base 60. The inner wall surfaces 61 a and 61 b on two orthogonal side surfaces adjacent to each other of the cube-shaped through hole 50 are the two-surface corner reflector 61. The dihedral corner reflector array optical element 6 includes a base 60 made of a transparent material, and a plurality of cube-shaped through holes 50 which are perforated on the base 60 and arranged in a grid pattern. As shown in FIG. 6, light rays that enter from one side of the base 60 and go to the inner wall surfaces 61 a and 61 b of the cube-shaped through hole 50 are reflected twice by the inner wall surfaces 61 a and 61 b, and the other of the cube-shaped through holes 50 It is injected from the side.

  A two-sided corner reflector optical element with a plurality of through-holes is produced by reversing the shape of an optical hole on a metal master plate by nano-processing, and reversing and transferring a metal such as aluminum or nickel by an electroforming method. It can be produced by removing the metal master plate.

  Furthermore, FIG. 7 shows a plan view of a part of one two-sided corner reflector array optical element 6 of four small panels of still another embodiment. FIG. 8 shows a perspective view of a part of the dihedral corner reflector array optical element 6 of FIG. 7 (projection 51 of a 4 × 4 pyramid). The double-sided corner reflector array optical element 6 includes a base 60 made of a transparent material and a plurality of truncated pyramid protrusions 51 integrally formed on the base 60 in a grid pattern. On the surface of the dihedral corner reflector array optical element 6, a plurality of pyramidal frustum projections 51 each having the same prismatic shape are arranged and arranged. Two of the four inner surfaces of the projecting portion 51 of the truncated pyramid are perpendicular to the main surface of the base 60, and the other two are tapered surfaces inclined with respect to the normal of the base 60. Two inner wall surfaces 61 a and 61 b which are adjacent and orthogonal to each other in the projecting portion 51 of the truncated pyramid are two-surface corner reflectors 61. By attaching a so-called “drawer taper” to the convex protrusions produced on the surface of the molded product, the two-surface corner reflector array optical element that is the molded product can be easily removed from the mold such as a stamper.

  As shown in FIG. 8, light rays that enter from the base 60 side and travel toward the inner wall surfaces 61 a and 61 b of the truncated pyramid projection 51 are reflected twice by the inner wall surfaces 61 a and 61 b, and from the upper surface of the truncated pyramid projection 51. It is injected.

  One dihedral corner reflector array optical element 6 having the truncated pyramid shaped protrusion 51 will be described in detail. FIG. 9 shows enlarged partial sectional views of the AA cross section and the BB cross section of FIG. FIG. 10 is a perspective view schematically showing the protrusion 51 of one truncated pyramid of the dihedral corner reflector array optical element.

  Each of the projections 51 of the truncated pyramid shown in FIG. 8 has two orthogonal side surfaces (mirror surfaces 61a and 61b) as the two-surface corner reflector 61, and other than the two mirror surfaces except the top surface and the bottom surface forming the two-surface corner reflector. The side surfaces 62 a and 62 b have a certain angle (inclined surface) from the normal line of the main surface of the base 60. In FIG. 8, the side surface 62a is not visible on the back side of the projection 51 of the truncated pyramid. The dimensions H, L, D and angle θ of the truncated pyramid protrusion 51 shown in FIG. 9 are as follows: height H = 170 μm, square top side L = 150 μm, spacing D = 10 μm, taper angle θ = 108 °. is there. The projecting portion 51 of the truncated pyramid has an inclined surface (an angle of 18 degrees from the surface perpendicular to the base) in consideration of a taper taper during resin molding, but this is a representative value, and the present invention is limited to this. is not.

  As shown in FIG. 10, the projection 51 of the truncated pyramid has a bottom surface 52 that is integral with the base 60 and a top surface 53 that has an area smaller than the bottom surface 52. The projecting portion 51 of the truncated pyramid includes a cube-shaped portion C including orthogonal side surfaces 61a and 61b of a two-sided corner reflector, and a tapered portion including side surfaces 62a and 62b other than the two-sided corner reflector integrated with the cube-shaped portion C as a plane. T. The truncated pyramidal protrusion 51 is formed as a plane (two-surface corner reflector 61) in which two orthogonal surfaces 61a, 61b of the four side surfaces 61a, 61b, 62a, 62b are perpendicular to the base 60, and Side surfaces 62a and 62b other than the two surfaces are inclined planes such that the plane (bottom surface) on the base 60 side of the truncated pyramid projection 51 is smaller on the plane opposite to the base side (upper surface). It has a formed structure. According to the resin molding method or hot press molding, a large number of protrusions 51 (one side is, for example, 50 to 200 μm) of a truncated pyramid (for example, a square bottom surface) are formed on a thin flat substrate 60 in plan view. Can be well formed. It is preferable that the inclination angle of the side surfaces 62a and 62b inclined from the normal line of the base 60 is not less than 5 degrees and not more than 25 degrees. If this inclination angle is 5 degrees or more, it acts as a so-called “drawing taper” of the resin molding method, and therefore, it is possible to easily remove the molded product of the two-surface corner reflector optical element 6 from the mold. Considering the removal of the two-surface corner reflector array optical element 6 from the stamper, it is preferable that the inclination angle is large. However, if the inclination angle is too large, the angle of the truncated pyramid projection 51 that is the light exit surface reflected by the two-surface corner reflector 61 is increased. As the area of the upper surface becomes smaller, the real image (real mirror image) of the object to be observed becomes darker. In addition, when the upper surface area is secured, the area of the bottom surface of the truncated pyramid protrusion 51 is increased and the number of the two-surface corner reflectors 61 per unit area is reduced. (Image) becomes dark. As a result of molding experiments using stampers with various inclination angles for these contradictory phenomena, it is preferable that the inclination angle is 5 degrees or more and 25 degrees or less. In the truncated pyramid projection 51, there are two side surfaces (excluding the top surface and the bottom surface) other than the two surfaces forming the two-surface corner reflector 61, and the both surfaces are inclined as described above. The inclination angles may or may not be equal.

  As shown in FIGS. 4, 6, and 8, in any of the two-surface corner reflector optical elements 6, the intersection line CL of the two orthogonal side surfaces 61 a and 61 b of each two-surface corner reflector 61 is on the main surface of the base 60. Orthogonal. Each of the two-sided corner reflectors 61 is formed on a regular grid point so that the inner angles formed by the orthogonal side surfaces 61a and 61b are all in the same direction on the base 60. In other words, all of the two-surface corner reflectors 61 are aligned in a matrix at the same pitch so as to be integrated with the substrate 60 so that the directions of the inner angles of the orthogonal side surfaces 61a and 61b are aligned in a certain direction perpendicular to the main surface of the substrate 60. Is formed. For example, the same plurality of rectangular two-surface corner reflectors 61 are arranged on the rectangular base 60 so as to be rectangular. The dihedral corner reflectors 61 do not necessarily need to be regularly aligned optically, but it is preferable to arrange them regularly in order to fabricate the dihedral corner reflector optical elements.

  As shown in FIG. 1, the four dihedral corner reflector array optical elements 6, 7, 8, and 9 have intersection lines CL (see FIGS. 4, 6, and 6) of the orthogonal side surfaces 61 a and 61 b of all the dihedral corner reflectors 61. The end surfaces 60 a of the base 60 are bonded to each other so that FIG. 8) is parallel to the normal line of the base 60. Adjacent ones of the two-surface corner reflector array optical elements 6 are arranged and bonded so that the orthogonal side surfaces 61a and the orthogonal side surfaces 61b of the plurality of two-surface corner reflectors 61 are aligned in parallel. Adjacent ones of the plurality of two-surface corner reflector array optical elements are arranged so that the directions of the inner angles of the orthogonal side surfaces 61a and 61b of the plurality of two-surface corner reflectors 61 are aligned. Large reflector array optical device 3 can be obtained.

[First Reflector Array Optical Device Manufacturing Method]
First, the pretreatment of the two-surface corner reflector array optical element before bonding will be described.

  FIG. 11 shows a two-sided corner reflector array optical element molded product for a two-sided corner reflector array optical element. For the purpose of extracting from the mold in the manufacturing process of the resin molding method, the two-sided corner reflector array optical element molded product M is a two-sided corner reflector 61 in which a plurality of two-sided corner reflectors 61 are integrally formed on the main surface of the base 60. An edge PR is provided around the array region Ma. Since the edge PR is not necessary for bonding, the surrounding edge PR is cut at the boundary of the array area Ma using a cutting means such as an acrylic cutter (a broken line indicates a cutting line) to form a rectangular shape from the array area Ma. A dihedral corner reflector array optical element 6 is obtained (FIG. 12). The two-surface corner reflector array optical element 6 has an end surface 60a parallel to the orthogonal side surfaces 61a and 61b of the two-surface corner reflector 61, as shown in FIG.

  In addition, as shown in FIG. 13, in order to obtain a two-sided corner reflector array optical element 6 having a desired shape, the peripheral edge PR and a part of the array region Ma may be cut (a broken line indicates a cutting line). it can. For example, the rectangular dihedral corner reflector array optical element 6 is obtained from the array region Ma by cutting along the bisector (45 °) of the inner angle of the dihedral corner reflector 61 and a line perpendicular to the bisector (see FIG. 14)). As shown in FIG. 14, the base 60 of the obtained rectangular two-surface corner reflector array optical element 6 has a flat end surface 60a that intersects the orthogonal side surfaces 61a and 61b at an angle of 45 degrees.

  Furthermore, as shown in FIG. 15, from the integrally molded two-surface corner reflector array optical element molded product, an angle φ of more than zero and less than 45 degrees with respect to one of the orthogonal side surfaces 61a and 61b in the substrate 60. It is also possible to cut out the rectangular dihedral corner reflector array optical element 6 having flat end surfaces 60a intersecting each other. 11 to 15, the entire set of the two-surface corner reflector 61 is represented in gray, and the direction of the inner angle of the two-surface corner reflector 61 is conceptually represented in a V shape.

  Here, the cut surface at the periphery of the dihedral corner reflector array optical element 6 remains as a rough surface with the edge PR and the like being cut. It is necessary to polish this rough cut surface to a mirror surface by polishing with an abrasive. Further, it is preferable to polish with a polishing agent so that the cut surface at the periphery of the dihedral corner reflector array optical element 6 is a flat surface so as not to be a wavy curved surface. As the polishing agent, a commercially available plastic cleaner (for example, manufactured by Soft99 Corporation) can be used. A polishing agent is included in a cloth or a becot and polished for a while, and finally, the cross section of the two-surface corner reflector array optical element 6 is washed with water. Further, when the abrasive has entered the array area Ma of the double-sided corner reflector 61, the abrasive adhered to the array area Ma of the double-sided corner reflector 61 is removed by an ultrasonic cleaner.

  Next, with reference to FIG. 16, a procedure for manufacturing a reflector array optical device by bonding the two two-sided corner reflector array optical elements 6 shown in FIG. 12 will be described. In FIG. 16, in order to suggest the direction of the dihedral corner reflector, the protrusion 51 of the 4 × 4 pyramid of the dihedral corner reflector array optical element 6 is emphasized and conceptually drawn. It is not an accurate indication of size.

  Next, as shown in FIG. 16 (a), a plurality of truncated pyramid shapes of the main surface portion of the base 60 adjacent to the end face 60a of the base 60 to be bonded to each of the two dihedral corner reflector array optical elements 6 are provided. The protrusion 51 (two-sided corner reflector 61) is covered with a water-soluble masking material 63.

  The masking material 63 may be provided so as to cover the entire arrangement portion of the truncated pyramidal protrusion 51, or may be provided so as to cover only a part of the vicinity of the end face 60a (for example, about 2 cm from the vicinity of the base section). When the optical adhesive enters and remains in the gap portion between the truncated pyramidal protrusions 51, the light propagating through the truncated pyramidal protrusion 51 of the manufactured reflector array optical device is reflected on the surface of the truncated pyramid protrusion 51. The reflection conditions will change. The masking material 63 has an effect of preventing this.

  If an adhesive obtained by emulsifying a vinyl acetate resin in water is used as the masking material 63, the adhesiveness is too strong, and the masking material permeated between the truncated pyramidal protrusions 51 may not be removed. On the other hand, if the rubber-based masking material has too weak adhesion, the coating does not work well and the rubber-based masking material may peel off from the edge of the substrate before joining the end surfaces 60a. In addition, since acrylic resin has low chemical resistance, when it is washed with ethanol or the like, cracks may occur in the base made of acrylic resin and the truncated pyramidal projection. Therefore, in this embodiment, the masking material 63 is a masking sol (registered trademark) manufactured by GSI Creos, which is a water-soluble drug that has adhesiveness to the substrate. Thus, the masking material can be easily peeled off by adhering the end faces 60a of the two-sided corner reflector array optical element 6 to each other and then ultrasonically washing them with water. The masking material 63 is a film-type peelable paint having solvent resistance to the optical adhesive and non-solubility to the two-sided corner reflector array optical element 6.

  Next, as shown in FIG. 16B, the end surfaces 60a of the bases to be bonded of the two two-sided corner reflector array optical elements 6 are brought into contact with each other, and the end surfaces 60a of the bonded bases are spanned. Adhesive tape 64 is attached to the main surface portion of base 60 and connected. Here, all of the two-surface corner reflectors 61 of the two two-surface corner reflector array optical elements 6 are perpendicular to the main surface of the substrate 60, and the directions of the inner angles of the orthogonal side surfaces 61a and 61b are aligned in a certain direction.

  Adhesive tape 64 (for example, cello tape (registered trademark)) is pasted on the base plane side without the truncated pyramidal projection 51. It is very important to eliminate the step in the thickness direction of the two-sided corner reflector array optical element 6 (substrate) with this adhesive tape 64 in order to make the joint inconspicuous. The adhesive tape 64 is stuck so as not to be wrinkled or to have air bubbles in the adhesive tape 64. The adhesive tape 64 has an effect of preventing the liquid optical adhesive from penetrating into the base plane side.

  Next, as shown in FIG. 16 (c), the end surfaces of the adjacent bases with the portion connected by the adhesive tape 64 before the two two-sided corner reflector array optical elements 6 are bonded together as a fulcrum (rotation center). The optical adhesive 70 in a liquid state is supplied between the end surfaces 60a. Here, the side on which the truncated pyramid-shaped protrusion 51 on the side opposite to the side where the adhesive tape 64 is applied is opened like a V-shape, and in the meantime, it is divided into several points with a tapered nozzle or the like, and liquid optical adhesion Agent 70 is supplied. As the optical adhesive 70, an ultraviolet curable resin having a refractive index substantially equal to the refractive index of a resin such as acrylic constituting the substrate 60 is used. As a result, the amount of light passing through the adhesive layer after bonding can be secured, and reflection of light at the boundary surface of the adhesive layer can be prevented, and the effect of making the seam inconspicuous can be obtained.

  As shown in FIG. 16 (d), a portion of the optical adhesive 70 is pushed out from the gap between the end surface 60a of the base and the skating material 63 onto the surface of the masking material 63, and the two two-sided corner reflector array optical elements 6 are moved. to paste together. Here, since it is held in advance by the adhesive tape 64, the main surfaces on the opposite side to the protruding portion side of the base 60 of the double-sided corner reflector optical element 6 to be bonded are aligned and bonded in such a positional relationship that no step is generated. I can do it. The two-sided corner reflector array optical elements 6 are pressed firmly from both sides toward each other, and the optical adhesive 70 is cured by irradiating ultraviolet rays as it is. Unnecessary optical adhesive 70 protrudes toward the truncated pyramidal protrusion 51 side of the base 60, but the masking material 63 protects the truncated pyramid protrusion 51, so that there is no problem.

  Next, the adhesive tape 64 is peeled off from the bonded two-surface corner reflector array optical element 6, and the masking material 63 together with a part of the optical adhesive 70 is removed from the main surface of the substrate 60 (FIG. 16E). As a result, two identical two-surface corner reflector array optical elements 6 having a plurality of truncated pyramid protrusions 51 in which the directions of the internal angles of the orthogonal side surfaces 61a and 61b are aligned in a certain direction are arranged in parallel on one plane. The joined reflector array optical device 3 is obtained.

  As shown in FIG. 16 (d), the masking material is applied when the two double-sided corner reflector array optical elements 6 are pushed in from both sides by applying the optical adhesive 70 slightly more than the amount necessary for bonding. The optical adhesive 70 swells on 63. As a result, the optical adhesive 70 cured by melting the masking material 63 at the time of ultrasonic cleaning is slightly lifted, so that it becomes easy to peel off the excess cured optical adhesive 70, and only between the end faces of the substrate. Filled with optical adhesive. In this way, it is more advantageous to peel off the unnecessary adhesive when the bonding portion of the optical adhesive 70 is raised on the masking material. Further, since the excess cured adhesive resin is removed, it is preferable that the sharpness reduction of the real mirror image due to the lens effect of the excess cured adhesive resin can be prevented. Further, it has been found that the adhesive surface of the dihedral corner reflector array optical element 6 should be polished as flat as possible. Even if an end face 60a is uneven, an ultraviolet adhesive that matches the refractive index is used.

  The process shown in FIG. 16 is repeated to produce a plurality of bonded two-face corner reflector array optical element 6 pairs, and the process shown in FIG. ), The same two-surface corner reflector array optical elements 6, 7, 8, 9 (four small panels) having a plurality of truncated pyramid protrusions 51 are arranged in parallel and in contact with each other on a single plane. The joined reflector array optical device 3 is obtained. Similarly, using the two-surface corner reflector array optical element 6 as shown in FIG. 3, the process shown in FIG. 16 is repeated to produce a plurality of bonded two-surface corner reflector array optical elements 6 and bonded together. By repeating the process shown in FIG. 16 between the two pairs, the same two-surface corner reflector array optical elements 6, 7, 8, having a plurality of rectangular parallelepiped protrusions 40, as shown in FIG. The reflector array optical device 3 in which 9 (four small panels) are arranged in parallel and in contact with each other on one plane is obtained. Similarly, by using the two-surface corner reflector array optical element 6 as shown in FIG. 5, the process shown in FIG. 16 is repeated to produce a plurality of bonded two-surface corner reflector array optical elements 6 and bonded together. By repeating the process shown in FIG. 16 between the two pairs, the same two-surface corner reflector array optical elements 6, 7, 8, having a plurality of rectangular parallelepiped protrusions 40, as shown in FIG. The reflector array optical device 3 in which 9 (four small panels) are arranged in parallel and in contact with each other on one plane is obtained.

[Second Reflector Array Optical Device Manufacturing Method]
First, a dihedral corner reflector array optical element 6 is prepared in which the end surface 60a of the substrate 60 is polished in a mirror shape similar to the first manufacturing method. Then, as shown in FIG. 18 (a), the main substrate 60 adjacent to the end surface 60a of the substrate 60 to be bonded in each of the two two-sided corner reflector array optical elements 6 as in the first manufacturing method. A plurality of two-surface corner reflectors 61 in the surface portion are covered with a masking material 63. Further, the plane rear surface opposite to the base 60 is covered with a masking material 63a.

  Next, a flat flat plate 65 serving as a surface plate and a slider plate S formed of parallel flat plates having the same thickness that are easy to slide with respect to the flat plate 65 are prepared. Then, as shown in FIG. 18B, on the same plane of the flat plate 65, the two end face reflectors 60a to which the two dihedral corner reflector array optical elements 6 are bonded via the slider plate S are arranged. The two-surface corner reflector array optical elements 6 are arranged so as to face each other and end surfaces 60a from the end surfaces of the slider plate S protrude. Before or after such arrangement, the optical adhesive 70 is supplied and attached to the end face 60a of the base to be bonded.

  Next, as shown in FIG. 18 (c), the end surfaces 60a of the bases face each other and are bonded together. The end surfaces of the slider plate S are not brought into contact with each other, and a gap is maintained. Here, the two double-sided corner reflectors are bonded together in such a positional relationship that the main surface opposite to the protruding portion side of the base 60 of the base 60 of the optical element 6 to be bonded is aligned (a step is not generated). The optical adhesive 70 is hardened by irradiating with ultraviolet rays in the state as it is pushed in from both sides of the array optical element 6 strongly. Unnecessary optical adhesive 70 protrudes on both sides of the base 60, but the masking material 63 protects the truncated pyramid-shaped projection 51 and the back surface opposite to the base 60 is covered with the masking material 63a. It doesn't matter.

  Next, the two-surface corner reflector optical element 6 bonded from the slider plate S on the flat plate 65 is taken up, and the bonded two-surface corner reflector array optical element is immersed in water in the same manner as in the first manufacturing method. Cleaning is performed to remove the masking materials 63 and 63a together with a part of the optical adhesive 70 from the plurality of two-sided corner reflectors 61 on the main surface of the base 60 (FIG. 18D). Thus, the reflector array optical device 3 is obtained in which two identical two-surface corner reflector array optical elements 6 having a plurality of truncated pyramidal protrusions 51 are arranged in parallel and in contact with each other on one plane.

[Third Reflector Array Optical Device Manufacturing Method]
First, the two-surface corner reflector array optical element 6 in which the end surface 60a of the base 60 similar to the first manufacturing method is polished into a mirror surface is prepared. Then, as shown in FIG. 19A, the base plate 60 adjacent to the end surface 60a of each base plate 60 to be bonded of each of the two dihedral corner reflector array optical elements 6 as in the first manufacturing method described above. A plurality of two-surface corner reflectors 61 in the main surface portion are covered with a masking material 63.

  Next, as shown in FIG. 19B, a transparent parallel plate 66 made of a transparent resin material such as acrylic is prepared, and an optical adhesive 70 is supplied on the same plane of the transparent plate 66. The optical adhesive 70 can be thinly spread on the transparent flat plate 66 using a bar coater or the like.

  Next, as shown in FIG. 19 (c), the two end face reflector array optical elements 6 on the transparent flat plate 66 supplied with the optical adhesive 70 are faced to each other. The optical adhesive 70 is supplied between the end surfaces 60a of the substrates to be bonded. The dihedral corner reflector array optical element 6 is disposed on the transparent flat plate 66 so that bubbles do not enter the optical adhesive 70.

  Next, as shown in FIG. 19 (d), the end surfaces 60 a of the bases are butted against each other on the optical adhesive 70 on the transparent flat plate 66, so that the transparent flat plate 66 and the two two-sided corner reflector array optics. The element 6 is bonded. Here, the two double-sided corner reflectors are bonded together in such a positional relationship that the main surface opposite to the protruding portion side of the base 60 of the base 60 of the optical element 6 to be bonded is aligned (a step is not generated). The optical adhesive 70 is hardened by irradiating with ultraviolet rays in the state as it is pushed in from both sides of the array optical element 6 strongly.

  Next, in the same manner as in the first manufacturing method, the two-surface corner reflector array optical element bonded to the transparent flat plate is immersed in water and subjected to ultrasonic cleaning, and the masking material 63 together with a part of the optical adhesive 70 is applied to the base 60. The main surface is removed from the plurality of two-surface corner reflectors 61 (FIG. 19E).

  Next, although not shown, if cutting (trimming) is performed along the outer edge of the two-sided corner reflector array optical element to which the transparent flat plate is bonded, the two two-sided corner reflector array optical elements are in contact with each other on one plane. A reflector array optical device arranged in parallel and joined is obtained.

  Furthermore, for example, as shown in FIG. 20, four identical two-surface corner reflector array optical elements 6, 7, 8, and 9 having a plurality of truncated pyramidal protrusions 51 are combined to form the two-surface corner reflector 61. A reflector array optical device having a transparent flat plate 66 bonded and superposed on the main surface of the opposite base 60 can be formed in the same manner as the manufacturing method shown in FIG. In this case, a transparent flat plate 66 having an area larger than the total area of the four identical rectangular two-surface corner reflector array optical elements 6, 7, 8, and 9 is prepared, and the corners and end faces of the bases of each element are prepared. It arrange | positions so that it may face each other, and it adhere | attaches so that all corners and end surfaces may face each other.

  Similarly, using the two-surface corner reflector array optical element 6 as shown in FIG. 3, as shown in FIG. 20B, the same two-surface corner reflector array optical element 6 having a plurality of rectangular parallelepiped protrusions 40, The reflector array optical device 3 is obtained in which 7, 8, 9 (four small panels) are arranged in parallel and joined to each other on one plane on the transparent flat plate 66.

  In the embodiment as described above, the end surface 60a for bonding the two-surface corner reflector array optical elements 6 to each other is formed as a surface perpendicular to the main surface on which the two-surface corner reflector is provided. However, the present invention is not limited to this, and it may be inclined. FIGS. 21A and 21B are the same as FIG. 17B except that the two-surface corner reflector array optical elements are bonded together in a state where the end surface 60aa is inclined in a complementary manner with respect to the main surface on which the two-surface corner reflector is provided. A reflector array optical device 3 similar to the embodiment shown in a) is shown. The dihedral corner reflector array optical elements 6, 7, 8, and 9 are preliminarily bonded to each other so that the main surface provided with the dihedral corner reflector is a continuous surface, and the end surface 60 aa has the same angle in the reverse direction. And are bonded by any one of the first to third manufacturing methods. The two-surface corner reflector array optical element 6 provided in this way is difficult to see the joint because the bonded end face of the substrate is not vertical and has an inclination angle. For example, it is particularly effective when only the base is thick such that the thickness is 3 mm or more.

  Also, if the thickness of the base is 3 mm or more with the two-sided corner reflector provided by the protruding portion, the back surface of the flat surface is polished and thinned so that the adhesion end face is not conspicuous. It is also effective. Further, since the adhesive protruding from the bonded cross section at the time of bonding can be removed by polishing, image disturbance due to the lens effect of the protruding adhesive can be eliminated.

  According to the bonding process using the adhesive tape 64 or the flat plate 65 or the transparent flat plate 66 in the manufacturing method of the first to third reflector array optical devices described above, the protrusions of the bases 60 of the adjacent two-surface corner reflector optical elements 6 are projected. Bonding can be performed in such a positional relationship that the principal surfaces on the opposite side to the part side are aligned (so that no step is generated). When a step is generated on the main surface of the adjacent base 60, the actual mirror image is distorted at the bonded portion. However, according to the above-described bonding process, the actual mirror image distortion can be prevented.

  FIG. 22 is a photomicrograph of the reflector array optical device actually produced according to the example of the present invention. This is because a rectangular acrylic two-surface corner reflector array optical element 6 having a flat end surface 60a intersecting at an angle of 45 degrees with respect to the orthogonal side surfaces 61a and 61b shown in FIG. 16 is a photograph of a part of the front surface of the reflector array optical device obtained by bonding using the method of the first embodiment described with reference to FIG. With this reflector array optical device, a large real mirror image forming optical system that forms a bright real image (real mirror image) of the object to be observed in the space on the viewer side can be realized.

6 2-sided corner reflector array optical element 6S element surface 40 cuboid protrusion 50 through-hole 51 pyramid 52 bottom surface 53 top surface 60 base 61 2-sided corner reflector 61a, 61b orthogonal side surface (mirror surface)
62a, 62b Side surfaces other than the two-sided corner reflector (tapered surface)
63 Masking material 64 Adhesive tape 65 Flat plate 66 Transparent flat plate 70 Optical adhesive CL Intersecting line of mirror surface C Cube-shaped part T Taper part

Claims (2)

A method of manufacturing a reflector array optical device that forms a real image of an observation object on one main surface side in a space on the other main surface side,
A plurality of two surfaces integrally formed on the substrate so that the substrate has at least two orthogonal side surfaces that are perpendicular to the main surface of the substrate and perpendicular to each other, and the directions of the internal angles of the orthogonal surfaces are aligned. Forming at least two two-sided corner reflector array optical elements comprising a corner reflector;
Coating the plurality of two-sided corner reflectors of the main surface portion of the base adjacent to the end face of the base to be bonded to each of the two two-sided corner reflector array optical elements with a masking material;
An optical adhesive is supplied between the end faces of the bases to be bonded, and a portion of the optical adhesive is pushed between the end faces of the bases to the surface of the masking material while the two two-side corners Bonding the reflector array optical element;
Removing the masking material from the plurality of two-sided corner reflectors of the main surface of the base together with a portion of the optical adhesive,
In the bonding step, before supplying an optical adhesive between the end faces of the bases, the end faces of the bases to be bonded of the two two-sided corner reflector array optical elements are brought into contact with each other and bonded. Including a step of attaching and connecting an adhesive tape to the main surface portion of the base in a positional relationship across the end faces of the base;
Before the two two-sided corner reflector array optical elements are bonded together, the end surfaces of the adjacent bases are opened with the portion connected by the adhesive tape as a fulcrum, and the end surfaces are between the end surfaces. After supplying an optical adhesive, the end surfaces of the base are closed and bonded together. The bonding step includes
An optical adhesive is supplied on the same plane of the transparent flat plate, and the two two-sided corner reflector array optical elements are bonded on the transparent flat plate supplied with the optical adhesive to the end face of the base to be bonded. Arranged so as to face each other, the optical adhesive is supplied between the end faces of the bases to be bonded, the end faces of the bases are butted toward each other, and the transparent flat plate and the two sheets The manufacturing method according to claim 1 , wherein the two-surface corner reflector array optical element is bonded.