Making an optic with a cladding
Embodiments related to making an optic comprising a cladding are disclosed. One example embodiment comprises forming a wedge-shaped light guide having opposing first and second faces and comprising a material having a first refractive index. The embodiment further comprises applying a cladding layer to the first face, and, applying an interface layer to the cladding layer. In this embodiment, the cladding layer has a second refractive index less than the first refractive index, and the interface layer has a third refractive index matched to the first refractive index.
1. A method for making an optic, the method comprising:
forming a wedge-shaped light guide having opposing first and second faces and comprising a material having a first refractive index;
applying a cladding layer to the first face, the cladding layer having a second refractive index less than the first refractive index; and
applying an interface layer to the cladding layer opposite the first face, the interface layer having a third refractive index matched to the first refractive index,
wherein applying an interface layer to the cladding layer comprises applying a turning film to the cladding layer via the interface layer.
2. The method of claim 1 , wherein the first refractive index is 1.4 or greater.
3. The method of claim 1 , wherein the second refractive index is 1.4 or less.
4. The method of claim 1 , the optic configured to attenuate a reflection of light having a median wavelength, wherein applying a cladding layer to the first face comprises applying a cladding layer of a thickness corresponding to an odd-integer multiple of one-half of a selected median wavelength.
5. The method of claim 1 , wherein applying the turning film to the cladding layer via the interface layer comprises applying an adhesive to one or both of the cladding layer and the turning film, a refractive index of the adhesive being substantially equal, after curing, to the first refractive index.
6. The method of claim 5 , wherein the adhesive is an ultraviolet-curing adhesive, the method further comprising irradiating at least the first face with ultraviolet light to cure the adhesive.
7. The method of claim 5 , wherein the adhesive is a polyacrylic adhesive.
8. The method of claim 1 , wherein applying the cladding layer to the first face comprises applying a moth-eye layer to the first face.
9. The method of claim 1 , wherein applying the cladding layer to the first face comprises applying a liquid or gel-like cladding formulation to at least the first face and allowing at least some of the liquid or gel-like cladding formulation to solidify.
10. The method of claim 9 , wherein the liquid or gel-like cladding formulation comprises one or more of a fluoropolymer dispersion, a fluoropolymer solution, and a fluoropolymer precursor.
11. The method of claim 9 , wherein the liquid or gel-like cladding formulation comprises a 100-percent-solids formulation.
12. The method of claim 9 , wherein the liquid or gel-like cladding formulation comprises an ultraviolet-curable component, the method further comprising irradiating at least the first face with ultraviolet radiation to cure the ultraviolet-curable component.
13. The method of claim 9 , wherein applying the cladding layer to the first face comprises applying the liquid or gel-like cladding formulation to the first face in a fixed-thickness layer by dragging a doctor blade along and at a fixed distance above the first face.
14. The method of claim 9 , wherein applying the cladding layer to the first face comprises spraying a liquid or gel-like cladding formulation onto at least the first face.
15. The method of claim 9 , wherein applying the cladding layer to the first face comprises at least partly immersing the wedge-shaped light guide in the liquid or gel-like cladding formulation, and, withdrawing the wedge-shaped light guide from the liquid or gel-like cladding formulation at an oblique angle with respect to a surface of the liquid or gel-like cladding formulation.
16. A method for making an optic, the method comprising:
forming a wedge-shaped light guide having opposing first and second faces and comprising a material having a first refractive index;
spraying a liquid or gel-like cladding formulation onto at least the first face and allowing at least some of the liquid or gel-like cladding formulation to solidify, the liquid or gel-like cladding formulation, after curing, having a second refractive index less than the first refractive index; and
applying a turning film to the cladding layer via an interface layer, the interface layer having a third refractive index matched to the first refractive index.
17. The method of claim 16 , further comprising dispersing one or more components of the liquid or gel-like cladding formulation ultrasonically while spraying.
18. A method for making an optic, the method comprising:
forming a wedge-shaped light guide having opposing first and second faces and comprising a material having a first refractive index;
at least partly immersing the wedge-shaped light guide in the liquid or gel-like cladding formulation and allowing at least some of the liquid or gel-like cladding formulation to solidify, the liquid or gel-like cladding formulation, after curing, having a second refractive index less than the first refractive index; and
applying a turning film to the cladding layer via an interface layer, the interface layer having a third refractive index matched to the first refractive index;
wherein applying the cladding layer to the first face comprises applying a liquid or gel-like cladding formulation to at least the first face.
19. The method of claim 18 , further comprising withdrawing the wedge-shaped light guide from the liquid or gel-like cladding formulation at an oblique angle with respect to a surface of the liquid or gel-like cladding formulation.