Method for fabricating fresnel lenses by selective application and removal of films on lens surfaces

• US 5,676,804 A
• Filed: 09/08/1995
• Issued: 10/14/1997
• Est. Priority Date: 09/13/1994
• Status: Expired due to Term

• Current Assignee: Sharp Kabushiki Kaisha (Hon Hai Precision Industry Co., Ltd.)
• Original Assignee: Sharp Kabushiki Kaisha (Hon Hai Precision Industry Co., Ltd.)
• Inventors: Tanaka, Naoyuki, Fujii, Akiyoshi, Hamada, Hiroshi
• Primary Examiner(s): Czaja, Donald E.
• Assistant Examiner(s): VINCENT, SEAN E
• Application Number:
  US08/525,082
• Time in Patent Office: 767 Days
• Field of Search: 427/448, 427/466, 427/468, 427/469, 427/472, 427/474, 427/526, 204/192.14, 204/192.28, 204/192.26
• US Class Current: 204/192.28
• CPC Class Codes: C23C 14/04 Coating on selected surface areas, e.g. using masks
• CPC Class Codes: C23C 14/08 Oxides C23C14/10 takes precedence
• CPC Class Codes: C23C 14/225 Oblique incidence of vaporised material on substrate
• CPC Class Codes: C23C 14/5873 Removal of material
• CPC Class Codes: G02B 3/08 with discontinuous faces, e.g. Fresnel lens diffractive Fresnel lenses G02B5/1876

Abstract

Particles of a lens coating material for forming a primary film are deposited from a direction toward which the surfaces of the lens prisms of a Fresnel lens face. Next, a light absorbing film is formed, conventionally, by sputtering, on both the lens surfaces on which the previously deposited primary film was formed and on the non-lens surfaces (on which no primary film was formed). This light absorbing film is intended to absorb types of undesirable or "invalid" light (e.g., "flaring light"). Subsequently, the films are removed from only the lens surfaces. Accordingly, a Fresnel lens having "invalid" light absorbing films only on the non-lens surfaces is more easily fabricated within a shorter time and at a reduced cost. Moreover, it is also possible to reduce the generation of "cone" and "rainbow" effects caused by "flaring light" when the Fresnel lens is used as a field lens of a projection-type image display device.

Claims

1. A method for fabricating a Fresnel lens having a lens main body for converging light passed through a lens surface comprising the steps of:

preparing the Fresnel lens main body with a plurality of prisms having lens surfaces and non-lens surfaces facing different directions from each other;

forming a primary film on each lens surface by depositing a material of said primary film only on said lens surfaces;

forming an invalid light absorbing film for restraining transmission of light on said lens surfaces and said non-lens surfaces; and

removing said primary film and the invalid light absorbing film from said lens surfaces.

2. The method for fabricating a Fresnel lens according to claim 1,

wherein the material of said primary film is deposited by evaporation.

3. The method for fabricating a Fresnel lens according to claim 1,

wherein the step of forming said primary film on each lens surface includes positioning an element with an aperture through said element in the vicinity of a deposition source of the material of said primary film for passing the material of said primary film from said source, through said aperture and onto said lens surface.

4. The method for fabricating a Fresnel lens according to claim 1,

wherein said "invalid" light absorbing film is formed by depositing a material of said "invalid" light absorbing film.

5. The method for fabricating a Fresnel lens according to claim 4,

wherein the material of said "invalid" light absorbing film is deposited by sputtering.

6. The method for fabricating a Fresnel lens according to claim 4,

wherein the lens has an axis and wherein the step of forming said invalid light absorbing film includes tilting a depositing direction of the material of said invalid light absorbing film at a predetermined angle relative to said axis and rotating said Fresnel lens main body on its own axis.

7. The method for fabricating a Fresnel lens according to claim 1,

wherein the material of said primary film is selected from the group consisting of metal and oxide,

the material of said "invalid" light absorbing film is selected from the group consisting of metal, oxide, carbon, sublimation pigment, and sublimation dye, and

the material of said primary film and the material of said "invalid" light absorbing film are soluble in different types of solvents.

8. The method for fabricating a Fresnel lens according to claim 1,

wherein said Fresnel lens main body is constructed so that the plurality of prisms are aligned in concentric circles on a flat base and that said non-lens surfaces tilt at a predetermined angle with respect to a first direction perpendicular to said flat base, and

wherein the step of forming said primary film includes:

using a mask having a fan-shaped opening section whose center angle is not larger than 90 degrees on a side on which said primary film is to be formed;

tilting a depositing direction of the material of said primary film at an angle not larger than 10 degrees from said first direction toward a second direction, wherein said first direction is perpendicular to said flat base and the second direction is perpendicular to the lens surfaces of said prisms located within said opening section; and

depositing the material of said primary film while rotating said Fresnel lens main body.

9. A method according to claim 1 wherein the step of depositing the primary film is accomplished by evaporation and the step of forming the invalid light absorbing film is accomplished by sputtering.

10. A method according to claim 9 wherein the step of evaporation includes electron beam evaporation.

11. A method according to claim 9 wherein the step of evaporation includes resistive heating evaporation.

12. A method according to claim 1 wherein the step of depositing the primary film is accomplished by evaporation and the step of forming the invalid light absorbing film is accomplished by plasma chemical vapor deposition.

13. A method according to claim 12 wherein the step of evaporation includes electron beam evaporation.

14. A method according to claim 12 wherein the step of evaporation includes resistive heating evaporation.

15. A method for fabricating a Fresnel lens having a lens main body for converging light passed through a lens surface comprising the steps of:

preparing the Fresnel lens main body with a plurality of prisms having lens surfaces and non-lens surfaces facing different directions from each other;

forming a primary film on each lens surface by depositing a material of said primary film only on said lens surfaces;

forming an invalid light absorbing film for restraining transmission of light on said lens surfaces and said non-lens surfaces;

removing said primary film and the invalid light absorbing film from said lens surfaces;

selecting the material of said primary film from the group consisting of iron oxides, Si and Ti;

the material of said invalid light absorbing film being selected from the group consisting of metal, oxide, carbon, sublimation pigment, and sublimation dye; and

the material of said primary film and the material of said invalid light absorbing film being soluble in different types of solvents.

16. A method for fabricating a Fresnel lens having a lens main body for converging light passed through a lens surface comprising the steps of:

preparing the Fresnel lens main body with a plurality of prisms having lens surfaces and non-lens surfaces facing different directions from each other;

forming a primary film on each lens surface by depositing a material of said primary film only on said lens surfaces;

forming an invalid light absorbing film for restraining transmission of light on said lens surfaces and said non-lens surfaces;

removing said primary film and the invalid light absorbing film from said lens surfaces;

the material of said primary film being selected from the group consisting of aluminum metal;

the material of said invalid light absorbing film being selected from the group consisting of sublimation pigment, sublimation dye, metal, oxide and carbon, said metal, oxide and carbon being insoluble in alkaline solvents;

the material of said primary film and the material of said invalid light absorbing film being soluble in different types of solvents; and

said primary film being caused to dissolve in said alkaline solvents in the step of removing said primary film from said lens surfaces.