Monomeric formulation for making polymer waveguides

• US 8,017,193 B1
• Filed: 08/06/2008
• Issued: 09/13/2011
• Est. Priority Date: 08/06/2008
• Status: Active Grant

• Current Assignee: HRL Laboratories LLC (The Boeing Co.)
• Original Assignee: HRL Laboratories LLC (The Boeing Co.)
• Inventors: Zhou, Chaoyin, Jacobsen, Alan J.
• Primary Examiner(s): Berman; Susan W
• Application Number:
  US12/187,201
• Time in Patent Office: 1,133 Days
• Field of Search: 522/42, 522/46, 522/48, 522/60, 522/173, 522/178, 522/180, 522/182, 522/44, 522/79, 522/174, 522/181, 522/184, 522/186, 430/281.1, 430/286.1, 430/269, 427/510
• US Class Current: 427/510
• CPC Class Codes: G02B 6/1221 made from organic materials
• CPC Class Codes: G02B 6/138 by using polymerisation
• 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
• CPC Class Codes: G03F 7/025 Non-macromolecular photopolymerisable compounds having carbon-to-carbon triple bonds, e.g. acetylenic compounds G03F7/075 takes precedence
• CPC Class Codes: G03F 7/027 Non-macromolecular photopolymerisable compounds having carbon-to-carbon double bonds, e.g. ethylenic compounds G03F7/075 takes precedence
• CPC Class Codes: G03F 7/031 Organic compounds not covered by group G03F7/029

Abstract

A monomeric formulation for creating self-propagating polymer optical waveguides and a system and a method of using the same. The monomeric formulation includes a plurality of unsaturated molecules, a molecule having a structure of R—X—H (e.g., X═O, S, N), and a photoinitiator. The monomeric formulation can further include a free radical inhibitor. The system includes a light source, a reservoir having a monomeric formulation and a patterning apparatus configured to guide a light beam from the light source into the monomeric formulation to form at least one self-propagating polymer waveguide.

Claims

1. A monomeric formulation for the fabrication of self-propagating polymer waveguides by photopolymerization, the monomeric formulation comprising:

a first molecule comprising at least one C═

C double bond or C≡

C triple bond;

a second molecule comprising two or more SH groups;

a photoinitiator selected from the group consisting of 2,2-dimethoxy-2-phenylacetophenone;

2-hydroxy-2-methylpropiophenone;

camphorquinone;

benzophenone; and

benzoyl peroxide, and combinations thereof; and

a free radical inhibitor comprising a compound selected from the group consisting of methylhydroquinone, ethylhydroquinone, methoxyhydroquinone, ethoxyhydroquinone, monomethylether hydroquinone, propylhydroquinone, propoxyhydroquinone, tert-butylhydroquinone, n-butylhydroquinone, and combinations thereof, the free radical inhibitor being present at a positive amount between 0-3% by weight of the monomeric formulation, and the free radical inhibitor being present in an amount sufficient to reduce polymerization of the monomeric formulation outside the waveguides while propagating the polymer waveguides.

2. The monomeric formulation of claim 1, wherein the first molecule is between 3% and 97% by weight of the monomeric formulation.

3. The monomeric formulation of claim 1, wherein the at least one C═

C double bond or C≡

C triple bond is located at a terminal position of the first molecule.

4. The monomeric formulation of claim 1, wherein the first molecule comprises one or more vinyl groups.

5. The monomeric formulation of claim 1, wherein the first molecule comprises at least one functional group selected from the group consisting of ethynyl, vinyl ether, vinyl ester, vinyl amide, vinyl triazine, vinyl isocyanurate, acrylate, methacrylate, diene, and triene.

6. The monomeric formulation of claim 1, wherein the first molecule is selected from the group consisting of pentaerythritol tetraacrylate;

2,4,6-triallyloxy-1,3,5-triazine;

triallyl-1,3,5-triazine-2,4,6-trione; and

combinations thereof.

7. The monomeric formulation of claim 1, wherein the second molecule is between 3% and 97% by weight of the monomeric formulation.

8. The monomeric formulation of claim 1, wherein the second molecule comprises an alkyl group or an ester group.

9. The monomeric formulation of claim 1, wherein the photoinitiator is more than 0% and less than 10% of total weight of the monomeric formulation.

10. The monomeric formulation of claim 1, wherein the photoinitiator generates free radicals under a light exposure by one of intramolecular bond cleavage or intermolecular hydrogen abstraction.

11. The monomeric formulation of claim 10, wherein the light exposure is produced from a light having a wavelength between 200 nm and 500 nm.

12. A monomeric formulation for the fabrication of self-propagating polymer waveguides by photopolymerization, the monomeric formulation comprising:

a first molecule comprising at least one functional group selected from the group consisting of ethynyl, vinyl ether, vinyl ester, vinyl amide, vinyl triazine, vinyl isocyanurate, acrylate, methacrylate, diene, and triene;

a second molecule comprising two or more —

SH groups;

a photoinitiator; and

a free radical inhibitor comprising a compound selected from the group consisting of methylhydroquinone, ethylhydroquinone, methoxyhydroquinone, ethoxyhydroquinone, monomethylether hydroquinone, propylhydroquinone, propoxyhydroquinone, tert-butylhydroquinone, n-butylhydroquinone, and combinations thereof, the free radical inhibitor being present at a positive amount between 0-3% by weight of the monomeric formulation, the free radical inhibitor being present in an amount sufficient to reduce polymerization of the monomeric formulation outside the waveguides while propagating the polymer waveguides.

13. The monomeric formulation of claim 12, wherein the first molecule is between 3% and 97% by weight of the monomeric formulation.

14. The monomeric formulation of claim 12, wherein the first molecule comprises at least one C═

C double bond or C≡

C triple bond located at a terminal position of the first molecule.

15. The monomeric formulation of claim 12, wherein the first molecule comprises one or more vinyl groups.

16. The monomeric formulation of claim 12, wherein the first molecule is selected from the group consisting of pentaerythritol tetraacrylate;

2,4,6-triallyloxy-1,3,5-triazine;

triallyl-1,3,5-triazine-2,4,6-trione; and

combinations thereof.

17. The monomeric formulation of claim 12, wherein the second molecule is between 3% and 97% by weight of the monomeric formulation.

18. The monomeric formulation of claim 12, wherein the second molecule comprises an alkyl group or an ester group.

19. The monomeric formulation of claim 12, wherein the photoinitiator is more than 0% and less than 10% of total weight of the monomeric formulation.

20. The monomeric formulation of claim 12, wherein the photoinitiator generates free radicals under a light exposure by one of intramolecular bond cleavage or intermolecular hydrogen abstraction.

21. The monomeric formulation of claim 20, wherein the light exposure is produced from a light having a wavelength between 200 nm and 500 nm.

22. The monomeric formulation of claim 12, wherein the photoinitiator is selected from the group consisting of 2,2-dimethoxy-2-phenylacetophenone;

2-hydroxy-2-methylpropiophenone;

camphorquinone;

benzophenone;

benzoyl peroxide; and

combinations thereof.

23. A system for forming at least one self-propagating polymer waveguide by photopolymerization, the system comprising:

a collimated light source for producing a light beam;

a reservoir having a monomeric formulation adapted to polymerize under a light exposure generated by the light beam; and

a patterning apparatus configured to guide a portion of the light beam into the monomeric formulation to form at least one polymer waveguide through a portion of a volume of the monomeric formulation,

wherein the monomeric formulation comprises;

a first molecule comprising at least one C═

C double bond or C≡

C triple bond;

a second molecule comprising two or more —

SH groups;

a photoinitiator selected from the group consisting of 2,2-dimethoxy-2-phenylacetophenone;

2-hydroxy-2-methylpropiophenone;

camphorquinone;

benzophenone; and

benzoyl peroxide; and

a free radical inhibitor comprising a compound selected from the group consisting of methylhydroquinone, ethylhydroquinone, methoxyhydroquinone, ethoxyhydroquinone, monomethylether hydroquinone, propylhydroquinone, propoxyhydroquinone, tert-butylhydroquinone, n-butylhydroquinone, and combinations thereof, the free radical inhibitor being present at a positive amount between 0-3% by weight of the monomeric formulation, and the free radical inhibitor being present in an amount sufficient to reduce polymerization of the monomeric formulation outside the waveguides while propagating the polymer waveguides.

24. A method for forming at least one polymer waveguide, the method comprising:

forming a volume of a monomeric formulation comprising a first molecule comprising at least one C═

C double bond or C≡

C triple bond;

a second molecule comprising two or more —

SH groups;

a photoinitiator; and

a free radical inhibitor comprising a compound selected from the group consisting of methylhydroquinone, ethylhydroquinone, methoxyhydroquinone, ethoxyhydroquinone, monomethylether hydroquinone, propylhydroquinone, propoxyhydroquinone, tert-butylhydroquinone, n-butylhydroquinone, and combinations thereof, the free radical inhibitor being present at a positive amount between 0-3% by weight of the monomeric formulation, and the free radical inhibitor being present in an amount sufficient to reduce polymerization of the monomeric formulation outside the waveguides while propagating the polymer waveguides;

securing a mask having at least one aperture between a collimated light source and the volume of the monomeric formulation; and

directing a collimated light beam from the collimated light source to the mask for a period of exposure time so that a portion of the collimated beam passes through the mask and is guided by the at least one aperture into the volume of the monomeric formulation to form at least one waveguide through a portion of the volume of the monomeric formulation.