Ultraprecise Single Point Cutting Technologies for Generation of Microstructures with Enhanced Retroreflective Characteristics

许多最近的技术进步表明，微光学代表了未来的关键技术之一。无论其功能作用如何，微光元件都必须以极高的精度大量生产。在各种各样可能的微光学设计中，反向反射微结构构成了一类特殊的特征，其特点是增强了反射回/返回大量入射光的能力。实现逆反射的一种常见方法是全内反射（TIR），这种现象本质上是推测具有不同折射率的介质之间界面处存在临界角。基于tir的后向反射器（rr）最广泛的应用是无处不在的尾灯，几乎安装在世界上每辆车上。然而，无论好坏，从某种意义上说，今天制造的结构表面RR与60年前几乎完全相同，长期存在的针束技术被用来制造唯一一种可以用它制造的RR设计，即角立方（CC）。虽然这种方法无疑是有效的，但它代表了对广为接受的“设计驱动制造”范式的重大偏离，在这种情况下，这种范式已被一种不太可取的“制造锁定设计”哲学所取代。为了解决这个问题，一种被称为超精密单点切割（USPC）的新技术被证明是产生非cc RRs的有效手段，更具体地说，以右三角棱镜（rtp）的形式。为了进一步提升USPC的技术/制造准备水平，当前提案将针对以下目标：i)开发具有增强光学性能的RR微结构；ii)开发高效的USPC切割和策略。为此，将使用各种各样的研究方法，实际范围从将表面质量纳入rs光学性能的虚拟模拟到将超声椭圆切割集成到一般RR制造过程中。在拟议的研究框架中产生的知识预计将促进下游发展，使加拿大制造商在制造反反射/微光学元件方面处于世界领先地位。预计通过当前提案取得的进展将使USPC达到成熟水平，能够使其未来扩展到非光学表面功能化领域。参与拟议研究的受训者预计将获得进一步促进和发展这一利基但目前代表性不足的加拿大经济部门所需的一套关键技能。

Numerous recent technological advancements suggest that microoptics represents one of the key enabling technologies of the future. Irrespective of their functional role, microoptical components have to be produced in large quantities and at extremely high levels of precision. Among the broad variety of microoptical designs possible, retroreflective microstructures constitute a special category of features characterized by enhanced capabilities to reflect back/return a significant amount of incoming/incident light. One of the common ways to achieve retroreflection involves total internal reflection (TIR), a phenomenon that essentially speculates the existence of the critical angle at the interface between media characterized by different refractive indices. The most widespread application of TIR-based retroreflectors (RRs) is represented by the ubiquitous taillights that are installed on virtually every vehicle in the world. However, for better or worse, structured-surface RRs are being manufactured today almost identically as 60 years ago in a sense that long-standing pin-bundling technology is in use to fabricate the only type of RR design that can be made with it, namely corner-cube (CC). While undoubtedly functional, this approach represents a significant deviation from the well-accepted "design-driven manufacturing" paradigm that has been replaced in this context by a less desirable "manufacturing-locked design" philosophy. To address this, a new technology termed as ultraprecise single point cutting (USPC) - with an inverted variant - was shown to be an effective mean to generate non-CC RRs, more specifically in the form of right triangular prisms (RTPs). To further elevate the technology/manufacturing readiness level of USPC, the following objectives will be targeted by the current proposal: i) develop RR microstructures characterized by an enhanced optical performance and, ii) develop efficient USPC cutting and strategies. For this purpose, a broad variety of investigational approaches will be used, practically ranging from the incorporation of the surface quality in the virtual simulation of the optical performance of the RRs to the integration of ultrasonic elliptical cutting into the general RR fabrication process. The knowledge to be generated in the framework of the proposed research is expected to facilitate downstream developments capable to position Canadian manufacturers among world leaders in fabrication of retroreflective/microoptical components. It is anticipated that the progress to be made through the current proposal will bring USPC to a level of maturity capable to enable its future extensions into the non-optical surface functionalization domain. The trainees to become involved in the proposed research are expected to acquire a critical set of skills required for further promotion and development of this niche, but presently underrepresented sector of Canadian economy.