Handbook of Plastic Optics Edited by Stefan Bäumer

Transcription

1 Handbook of Plastic Optics. Stefan Bäumer (Ed.) Copyright 2005 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim ISBN: Handbook of Plastic Optics Edited by Stefan Bäumer

2 Handbook of Plastic Optics Edited by Stefan Bäumer

3 Editor Stefan Bäumer Philips Center for Industrial Technology (CFT), Industrial Optics Eindhoven, The Netherlands & All books published by Wiley-VCH are carefully produced. Nevertheless, authors, editors, and publisher do not warrant the information contained in these books, including this book, to be free of errors. Readers are advised to keep in mind that statements, data, illustrations, procedural details or other items may inadvertently be inaccurate. Library of Congress Card No.: applied for British Library Cataloguing-in-Publication Data A catalogue record for this book is available from the British Library. Cover Picture Picture courtesy of WAHL optoparts GmbH, Bibliographic information published by Die Deutsche Bibliothek Die Deutsche Bibliothek lists this publication in the Deutsche Nationalbibliografie; detailed bibliographic data is available in the Internet at < WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim All rights reserved (including those of translation into other languages). No part of this book may be reproduced in any form nor transmitted or translated into machine language without written permission from the publishers. Registered names, trademarks, etc. used in this book, even when not specifically marked as such, are not to be considered unprotected by law. Printed in the Federal Republic of Germany. Printed on acid-free paper. Typesetting Kühn & Weyh, Satz und Medien, Freiburg Printing Druckhaus Darmstadt GmbH, Darmstadt Bookbinding Litges & Dopf Buchbinderei GmbH, Heppenheim ISBN-13: ISBN-10:

4 V Contents List of Contributors IX 1 Introduction 1 2 Optomechanics of Plastic Optical Components Introduction Configuration of Plastic Optical Elements Single-Function Elements Elements with Integrated Fixation Features High Functional Integration Mounting Plastic Optical Elements Dimensional Stability Structural Stability Thermal Stability Moisture Expansion Tolerancing Tolerance Budgeting and Allocation Typical Tolerances and Specifications for Plastic Optics Optomechanical Simulation of Plastic Optical Elements Integrated Optomechanical Analysis Thermoelastic Analysis Stress Birefringence Analysis Thermo-optic Analysis Moisture Absorption Analysis Mold Flow Analysis 32 3 Tooling for Injection Molded Optics Introduction Principles Main Parts of an Injection Mold Gate and Runner Design for Optical Molded Parts Hot and Cold Runner Molds 39 Handbook of Plastic Optics. Stefan Bäumer (Ed.) Copyright 2005 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim ISBN:

5 VI Contents Ejector Design Heating and Cooling Mold Height, Opening Stroke, and Ventilation Number of Cavities Consideration of Shrinkage Materials for Injection Molds Design Steps of Injection Molds for Plastic Optics Molding Variations Two-Component Injection Molding Compression Molding Optical Mold Inserts Steel Polishing Galvanic Replication Diamond-Turning Technology Insert Quality and Molded Parts Ultra-precision Machine Tools for Mold-Making Characteristics of an UP Machine Tool Some Words about the Environment Basic Process Features Tooling for Precision Typical Machine Configurations Material-Related Limitations 62 4 Metrology of Injection Molded Optics Introduction Dimensional Metrology Optical Metrology General Interferometry Interferometry and Aspheres Interferometry and Strong Aspheres Double- and Single-Pass Interferometers Kodak Example Microscope Interferometers Shack Hartmann Sensors Other Wavefront Sensors Shearing Interferometer Deflectometry Tactile Profiling Centration Measurement Optical Centration Measurement Image Processing Mechanical Centration Measurement Centration of Multi-element Systems Birefringence 95

6 Contents VII 4.7 Custom Setups SALDO Double-Mirror System High-Throughput Modulation Transfer Function Testing of CMOS Camera Modules Concluding Remarks Optical Plastics Introduction Quality Requirements for Optical Plastics Transparency Refractive Index Birefringence Stability Plastics Acrylate Polymers Polycarbonate Cycloolefin Polymer Other Resin Materials Summary Coating on Plastics Introduction Deposition Techniques Physical Vapor Deposition (PVD) Plasma-Enhanced Chemical Vapor Deposition (PECVD) Wet-Chemical Coating (Sol Gel Coating) Plasma Effects on Polymers Effects Caused by UV Radiation Ion Bombardment Effects Coating Adhesion Stresses and Crack Formation Test and Qualification Methods Optical Properties Adhesion Environmental Durability Abrasion Resistance Antireflective Properties Optical Interference Coatings AR Coating Design for Plastics AR Surface Structures Additional Functional Coatings Mirrors Antistatic Layers 173

7 VIII Contents Hydrophobic Topcoats Coating with Different Thermoplastics Poly(Methyl Methacrylate) Polycarbonate Summary and Outlook 176 Index 181

8 IX List of Contributors Stefan Bäumer Philips CFT Vision Optics Sensors / Industrial Optics SAQ p311 Postbus MD Eindhoven The Netherlands s.m.b.baumer@philips.com (Chapters 1 and 4) Thomas Bauer Wahl Optoparts GmbH Straße der Deutschen Einheit Triptis Germany t.bauer@wahl-optoparts.de (Sections ) Dieter Marschall Precitech Ultra Precision Technology B.V. Am Hirtengarten Haundorf Germany dmarschall@precitech.com (Section 3.5) Koji Minami Zeon Corporation R&D Center 1-2-1, Yako Kawasaki-ku Kawasaki-shi Kawasaki-ken, Japan minami@zeon.co.jp (Chapter 5) Michael Pfeffer Master Course Optical Systems Engineering Dept. Physical Engineering FH Ravensburg-Weingarten Postfach Weingarten Germany pfeffer@fh-weingarten.de (Chapter 2) Ulrike Schulz Fraunhofer Institut IOF Optical Coatings group Albert Einstein Str Jena Germany ulrike.schulz@iof.fraunhofer.de (Chapter 6) Handbook of Plastic Optics. Stefan Bäumer (Ed.) Copyright 2005 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim ISBN:

9 X List of Contributors Stefan Bäumer is working at the Philips Centre for Industrial Technology (CFT) as senior optical designer. His main areas of interest are in design and metrology of injection molded optics. He is working in close cooperation with Philips High Tech Plastics (HTP). Thomas Bauer is working at Wahl Optoparts GmbH Triptis, a plastic optics manufacturer. He is currently responsible for the plastic coating department. Dieter Marschall is Area Sales & Service Manager for Germany, Austria & Switzerland at Precitech B.V., the European subsidiary of Precitech Inc. (USA), one of the world s leading manufacturer of Single Point Diamond Machining Systems for turning-, milling- and grinding operation. Koji Minami is working at Zeon Corporation as senior researcher. His main responsibility is application development of Cyclo Olefin Polymer (COP): ZEONEX / ZEONOR. Michael Pfeffer is teaching at the University of Applied Sciences in Weingarten as professor of optical engineering. His major areas of interest are finite element analysis in opto-mechanical engineering, diffractive optics and nanometric structuring of optical surfaces. He is currently dean of the master course Optical Systems Engineering. Ulrike Schulz received her diploma degree in chemistry in 1986 and her PhD (Dr. rer. nat.) in 1993 from the University of Jena, Germany. She is responsible for the group Coatings on Polymers at the Fraunhofer Institute of Applied Optics and Precision Engineering in Jena and has authored a number of papers and patents on processes for polymer coating and coating design.