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REPLICATION OF DIFFRACTION GRATINGS BY EMBOSSING TECHNIQUES

IP.com Disclosure Number: IPCOM000024937D
Original Publication Date: 1982-Dec-31
Included in the Prior Art Database: 2004-Apr-04
Document File: 2 page(s) / 114K

Publishing Venue

Xerox Disclosure Journal

Abstract

Replication of optical elements incorporating surface relief gratings have typically been accomplished by using a cold molding process. In this process, a master grating or optical element is coated with a release agent and a blocking layer (normally an evaporated metal film). The coated master is then epoxied to a suitable substrate and the epoxy cured. When the pieces are separated, a replica of the information contained on the master surface is transferred to the substrate via the cured epoxy film. The master is recycled to produce additional replicas. Large scale volume production by this technique is relatively expensive since a large number of submasters are needed and because the process requires a vacuum deposition step and a time consuming curing step.

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KEROX DISCLOSURE JOURNAL

REPLICATION OF DIFFRACTION GRATINGS BY EMBOSSING TECHNIQUES
Charles J. Kramer

Proposed Classification
U.S. C1. 350/162R Int. CI. G02b 5/18

F/G. I

F/G. 2

Volume 7 Number 6 November/December 1982 379

[This page contains 1 picture or other non-text object]

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REPLICATION OF DIFFRACTION GRATINGS BY EMBOSSING TECHNIOL'ES (Cont'd)

Replication of optical elements incorporating surface relief gratings have typically been accomplished by using a cold molding process. In this process, a master grating or optical element is coated with a release agent and a blocking layer (normally an evaporated metal film). The coated master is then epoxied to a suitable substrate and the epoxy cured. When the pieces are separated, a replica of the information contained on the master surface is transferred to the substrate via the cured epoxy film. The master is recycled to produce additional replicas. Large scale volume production by this technique is relatively expensive since a large number of submasters are needed and because the process requires a vacuum deposition step and a time consuming curing step.

An alternate technique for large scale replication is embossing. In this method, a relief replica of a master is made and the information contained therein is then impressed onto the surface of a thermoplastic substrate in a stamping operation. A particular problem in this operation has been warpage of the thermoplastic substrate during or after the embossing process. This is because the substrate has been performing the dual function of providing a base support as well as accepting the informatio...