SYSTEMS AND METHODS FOR FABRICATING DISPLACEMENT SCALES

• US 20100196607A1
• Filed: 06/18/2008
• Published: 08/05/2010
• Est. Priority Date: 06/19/2007
• Status: Active Grant

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Ehnes, Dale L., Biyikli, Levent, Campbell, Alan B., Carlson, Daniel H., Aguirre, Luis A., Wertz, Daniel S.
• Granted Patent: US 9,513,412 B2
• Time in Patent Office: Days
• US Class Current: 427/359
• CPC Class Codes: G01D 5/34707 Scales; Discs, e.g. fixation, fabrication, compensation
• CPC Class Codes: G02B 5/124 plural reflecting elements forming part of a unitary plate or sheet
• CPC Class Codes: G03F 7/0005 Production of optical devices or components in so far as characterised by the lithographic processes or materials used therefor

Abstract

Methods and systems for forming a displacement scale comprising TIR prisms on a substrate are described. A system for forming the displacement scale includes one or more rollers having a pattern of total internal reflection (TIR) prism features in negative relief. As the rollers are rotated, the scale is formed on the substrate. The rollers may also include pattern features in negative relief. Rotation of the rollers simultaneously forms the displacement scale and the pattern features on the substrate. The TIR prism features of the displacement scale may be oriented to provide measurement of one or more of lateral displacement, longitudinal displacement and angular displacement.

Claims

1. A system for forming a displacement scale on a substrate, comprising:

one or more rollers having total internal reflection (TIR) prism features in negative relief; and

a drive mechanism configured to rotate the rollers so that the displacement scale comprising the TIR prism features is formed on the substrate.

2. The system of claim 1, wherein the rollers also have pattern features in negative relief and rotation of the rollers simultaneously forms the displacement scale and the pattern features on the substrate.

3. The system of claim 1, further comprising a dispenser configured to dispense a material on a surface of the substrate and wherein rotation of the rollers forms the displacement scale comprising the TIR prism features in the material on the substrate.

4. The system of claim 3, wherein the material comprises a UV curable resin.

5. The system of claim 3, wherein the material comprises a castable polymer.

6. The system of claim 3, wherein the material comprises a curable material.

7. The system of claim 3, further comprising a curing station configured to cure the TIR prism features of the scale.

8. The system of claim 7, wherein the curing station comprises a UV light source.

9. The system of claim 7, wherein:

the material comprises a thermally curable material; and

the curing station comprises a heat source.

10. The system of claim 1, further comprising:

one or more additional rollers including additional pattern features in negative relief; and

an additional drive mechanism configured to rotate the one or more additional rollers so that additional pattern features are formed on the substrate.

11. The system of claim 10, wherein the pattern features are formed simultaneously with the formation of the displacement scale.

12. The system of claim 10, wherein:

the rollers have a first set of pattern features in negative relief and rotation of the rollers simultaneously forms the displacement scale and the first set of pattern features on the substrate; and

the scale is configured to facilitate transfer of the additional pattern features in registration with the first set of pattern features.

13. The system of claim 1, wherein the substrate comprises a flexible web.

14. The system of claim 1, wherein the substrate comprises a rigid material.

15. The system of claim 1, wherein the substrate comprises a polymer.

16. The system of claim 1, wherein the displacement scale comprises a first set of TIR prisms configured to measure lateral displacement and a second set of TIR prisms configured to measure longitudinal displacement.

17. The system of claim 16, wherein the first and second sets of prisms are arranged in a checkerboard pattern.

18. The system of claim 1, wherein the displacement scale is configured to measure angular displacement.

19. A method of forming a displacement scale comprising TIR prism features on a substrate, comprising:

bringing the substrate into contact or close proximity with the one or more rollers having total internal reflection (TIR) prism features in negative relief; and

rotating the rollers relative to the substrate so that the displacement scale comprising TIR prism features is formed on a surface of the substrate.

20. The method of claim 19, further comprising:

dispensing a material on the substrate surface; and

wherein rotating the rollers so that the scale is formed comprises rotating the rollers so that the TIR prism features are formed in the material.

21. The method of claim 19, further comprising forming pattern features on the substrate concurrently with formation of the TIR prism features.

22. The method of claim 21, further comprising:

depositing an additional material on an opposite surface of the web or on one or more additional rollers to form additional web pattern features, the one or more additional rollers having additional web pattern features in negative relief;

bringing the web in contact or close proximity with the one or more additional rollers; and

forming, on the opposite surface of the web, the additional web pattern features.

23. The method of claim 22, further comprising maintaining registration between the web pattern features and the additional web pattern features using the scale.

24. A tool configured to form a scale on a substrate, the tool comprising a roller having total internal reflection (TIR) prism features arranged and pattern features in negative relief, the roller configured to simultaneously form a scale, comprising TIR prism features, and pattern features on a substrate when the roller is brought into contact or close proximity with the substrate.

25. The tool of claim 24, wherein the TIR prism features comprise right regular prisms.

26. The tool of claim 24, wherein the TIR prism features comprise a checkerboard pattern including a first set of features configured to measure longitudinal displacement and a second set of features configured to measure lateral displacement.

27. The tool of claim 24, wherein a distance between the prism peaks is about 40 μ

m.

28. The tool of claim 24, wherein a distance between the prisms is about 20 μ

m.